Cellulose ester multilayer interlayers

ABSTRACT

An interlayer structure having a cellulose ester layer for use in structural laminates is described herein. The cellulose ester layer provides rigidity and support to multilayer interlayers comprising an array of different layers. Due to the diverse properties of the cellulose ester layers, the present interlayers can be useful in producing structural laminates having high stiffness and which possess good optical clarity for a variety of applications, including outdoor structural applications.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/306,757, filed on Mar. 11, 2016, the disclosure ofwhich is incorporated herein by reference in its entirety.

BACKGROUND

1. Field of the Invention

The present invention generally relates to interlayers and laminatescomprising a cellulose ester. More particularly, the present inventiongenerally relates to structural interlayers and laminates comprising atleast one layer that contains a cellulose ester.

2. Description of the Related Art

Generally, multiple layer glass panels comprise a laminate comprised ofan interlayer or multilayer interlayer or interlayers sandwiched betweentwo panes of glass. In some applications, a laminate may comprise onlyone pane of glass or other rigid substrate. The laminated multiple layerglass panels are commonly utilized in architectural window applications,in the windows of motor vehicles and airplanes, and in photovoltaicsolar panels. The first two applications are commonly referred to aslaminated safety glass. Typically, the main function of the interlayerin the laminated safety glass is to absorb energy resulting from impactor force applied to the glass, keep the layers of glass bonded even whenthe force is applied and the glass is broken, and prevent the glass frombreaking up into sharp pieces. Additionally, the interlayer generallygives the glass a much higher sound insulation rating, reduces UV and/orIR light transmission, and enhances the aesthetic appeal of theassociated window.

The interlayer is generally produced by mixing a polymer resin, such aspoly(vinyl acetal), with one or more plasticizers and melt processingthe mix into an interlayer by any applicable process or method known toone of skill in the art. After the interlayer or multilayer interlayeris formed, it is typically collected and rolled for storage and forlater use in multiple layer glass panels.

Interlayers can be incorporated into multiple layer glass panels usingvarious techniques known in the art. For example, at least onemultilayer interlayer can be placed between two substrates and anyexcess interlayer can be trimmed from the edges, thereby creating anassembly. It is not uncommon for multiple interlayers to be placedwithin the two substrates thereby creating a multiple layer glass panelwith multiple interlayers. Subsequently, air can be removed from theassembly by an applicable process or method known to one of skill in theart, e.g., through nip rollers, vacuum bag, vacuum ring, or anotherde-airing mechanism. Additionally, the interlayer can be partially pressbonded to the substrates by any method known to one of ordinary skill inthe art. In a last step, in order to form a final unitary structure,this preliminary bonding can be rendered more permanent by a hightemperature and pressure lamination process known to one of ordinaryskill in the art such as, but not limited to, autoclaving.

An emerging market in architectural laminated glass requires interlayerswith structural properties such as load bearing ability. Such aninterlayer is Eastman's Saflex™ DG, which is made of plasticizedpolyvinyl butyral (“PVB”). Generally, Saflex™ DG interlayers are stifferproducts than standard PVB interlayers and this higher stiffness allowslaminates made with Saflex™ DG interlayer to sustain higher loads.Alternatively, Saflex™ DG interlayers can be used to allow a reductionin the glass thickness while achieving the same laminate loading.

Consequently, higher performance interlayers are desirable as moreapplications requiring stiffer interlayers are emerging (e.g., singleside balcony laminates, canopies, staircases, and support beams).However, many of the commercially-available PVB interlayers exhibitdeficiencies in terms of processability and/or functionality. Further,the attraction of glass in many of these structural applications is theclarity of the glass panel. Thus, the PVB layers must also not hinderthe optical properties of the structural glass articles in which theyare incorporated.

Accordingly, there is a need for an interlayer for use in structurallaminates that can provide the desired structural support and notcompromise the optical properties of the laminate.

SUMMARY

One or more embodiments of the present invention concern a multilayerinterlayer comprising: (a) a non-cellulose ester layer comprising apoly(vinyl acetal) resin; (b) a cellulose ester layer comprising atleast one cellulose ester having a hydroxyl content of at least 0.5weight percent based on the entire weight of the cellulose ester,wherein said cellulose ester layer has a glass transition (“Tg”)temperature of at least 50° C.; and (c) an adhesive coating comprisingat least one silanol-containing agent, wherein said adhesive coating isat least partially interposed between said non-cellulose ester layer andsaid cellulose ester layer.

One or more embodiments of the present invention concern a multilayerinterlayer comprising: (a) a first non-cellulose ester layer comprisinga poly(vinyl acetal) resin; (b) a cellulose ester layer comprising atleast one cellulose ester having a hydroxyl content of at least 0.5weight percent based on the entire weight of the cellulose ester,wherein said cellulose ester layer has a glass transition (“Tg”)temperature of at least 50° C.; (c) a first adhesive coating comprisingat least one silanol-containing agent, wherein said first adhesivecoating is at least partially interposed between said firstnon-cellulose ester layer and said cellulose ester layer; (d) a secondnon-cellulose ester layer comprising a poly(vinyl acetal) resin; and (e)a second adhesive coating comprising at least one silanol-containingagent, wherein said second adhesive coating is at least partiallyinterposed between said second non-cellulose ester layer and saidcellulose ester layer.

One or more embodiments of the present invention concern a multilayerinterlayer comprising: (a) a non-cellulose ester layer comprising apoly(vinyl acetal) resin and a plasticizer; (b) a cellulose ester layercomprising at least one cellulose ester having a hydroxyl content of atleast 0.5 weight percent based on the entire weight of the celluloseester and a plasticizer, wherein said cellulose ester layer has a glasstransition (“Tg”) temperature of at least 70° C.; and (c) an adhesivecoating comprising at least one silanol-containing agent, wherein saidadhesive coating is at least partially interposed between saidnon-cellulose ester layer and said cellulose ester layer.

One or more embodiments of the present invention concern a laminatecomprising the multilayer interlayer.

BRIEF DESCRIPTION OF THE FIGURES

Embodiments of the present invention are described herein with referenceto the following drawing figures, wherein:

FIG. 1 depicts a structural glass laminate containing a multilayerinterlayer of the present invention;

FIG. 2 depicts a structural glass laminate containing a multilayerinterlayer of the present invention;

FIG. 3 is a cross-sectional view of a tapered interlayer configured inaccordance with one embodiment of the present invention, where variousfeatures of the tapered interlayer are labeled for ease of reference;

FIG. 4 is a cross-sectional view of a tapered interlayer having atapered zone that extends over the entire width of the interlayer, wherethe entire tapered zone has a constant wedge angle and a linearthickness profile;

FIG. 5 is a cross-sectional view of a tapered interlayer having atapered zone that extends over part of the width of the interlayer and aflat edge zone that extends over part of the width of the interlayer,where the tapered zone includes a constant angle zone and a variableangle zone;

FIG. 6 is a cross-sectional view of a tapered interlayer having atapered zone that extends over part of the width of the interlayer andtwo flat edge zones that extend over part of the width of theinterlayer, where the tapered zone includes a constant angle zone andtwo variable angle zones;

FIG. 7 is a cross-sectional view of a tapered interlayer having atapered zone that extends over part of the width of the interlayer andtwo flat edge zones that extend over part of the width of theinterlayer, where the tapered zone is formed entirely of variable anglezones having a curved thickness profile;

FIG. 8 is a cross-sectional view of a tapered interlayer having atapered zone that extends over the entire width of the interlayer, wherethe tapered includes three constant angle zones spaced from one anotherby two variable angle zones;

FIG. 9 is a cross-sectional view of a tapered interlayer having atapered zone that extends over part of the width of the interlayer andtwo flat edge zones that extend over part of the width of theinterlayer, where the tapered zone includes three constant angle zonesand four variable angle zones;

FIG. 10 is a graph depicting the haze measurements of the EVA/CAP/EVAinterlayers produced in Example 1;

FIG. 11 is a graph depicting the yellowness index measurements of theEVA/CAP/EVA interlayers produced in Example 1;

FIG. 12 is a graph depicting the light transmission measurements of theEVA/CAP/EVA interlayers produced in Example 1;

FIG. 13 is a graph depicting the haze measurements of the EVA/CAP/EVAinterlayers produced in Example 1;

FIG. 14 is a graph depicting the yellowness index measurements of theEVA/CAP/EVA interlayers produced in Example 1;

FIG. 15 is a graph depicting the light transmission measurements of theEVA/CAP/EVA interlayers produced in Example 1;

FIG. 16 is a graph depicting the compressive shear adhesion measurementsof the EVA/CAP/EVA interlayers produced in Example 1;

FIG. 17 is a graph depicting the mean break height of the EVA/CAP/EVAinterlayers produced in Example 1;

FIG. 18 is a graph comparing the mean break height of interlayerscomprising formulated EVA and unformulated EVA; and

FIG. 19 is a graph comparing the mean break height of interlayerscomprising formulated EVA and unformulated EVA.

DETAILED DESCRIPTION

The present invention generally relates to interlayers that exhibitsuperior stiffness and that provide desirable optical properties whenincorporated into structural laminates. More particularly, the presentinvention generally relates to structural interlayers comprising atleast one layer containing a cellulose ester. As discussed in furtherdetail below, the cellulose esters are able to form layers or sheetsthat may be incorporated in various types of interlayers comprising avast array of different layers. The cellulose ester layers describedherein can provide desirable structural support to the interlayer andstructural laminate, while maintaining the desired optical propertiessought in such laminates.

Generally, the present invention relates to cellulose ester layers andinterlayers having improved adhesion to glass, metal, and otherinorganic materials. In various embodiments, the cellulose ester layersand interlayers described herein can include at least one celluloseester layer comprising a cellulose ester. Due to their desirableproperties such as higher glass transition temperature and stiffness,the cellulose ester layers described herein can be used in structurallaminates, which are finding increasing use in the present market.

As used herein, the term “cellulose ester layer” refers to one or morecellulose ester resins, optionally combined with one or moreplasticizers, that have been formed into a sheet. As discussed below,these cellulose ester layers may include one or more additionaladditives. As used herein, the term “interlayer” refers to a single ormultiple layer polymer sheet that may be suitable for use with at leastone rigid substrate to form a multiple layer panel. The terms“single-sheet” and “monolithic” interlayer refer to interlayers formedof one single sheet, while the terms “multiple layer” and “multilayer”interlayer refer to interlayers having two or more sheets that arecoextruded, laminated, or otherwise coupled to one another.

The term “multilayer interlayer” refers to polymer interlayerscomprising at least two polymer layers. In some embodiments, at leastone layer of the multilayer interlayer can be a cellulose ester layerand at least one of those layers can be a non-cellulose ester layer(e.g., poly(vinyl acetal), thermoplastic polyurethane, ionomer and/orethylene vinyl acetate). As discussed further below, the multiple layersmay be separately extruded layers, co-extruded layers, or anycombination of separately and co-extruded layers. Thus, the multilayeredinterlayer could comprise, for example, two or more single-layerinterlayers combined together (“plural-layer interlayer”); two or morelayers co-extruded together (“co-extruded interlayer”); two or moreco-extruded interlayers combined together; a combination of at least onesingle-layer interlayer and at least one co-extruded interlayer; and acombination of at least one plural-layer interlayer and at least oneco-extruded interlayer.

The various layers that can form the interlayers and structurallaminates described herein are discussed in further detail below.

The Cellulose Ester Layer Properties of the Cellulose Esters

The following description of the cellulose esters applies to all of thecellulose ester layers and the cellulose esters used in the interlayersdisclosed herein.

As discussed above, the cellulose ester layers described herein cancomprise one or more cellulose esters. The cellulose esters useful inthe present invention can be prepared using techniques known in the artor can be commercially obtained, e.g., from Eastman Chemical Company,Kingsport, Tenn., U.S.A. Generally, the cellulose esters can be producedby any method known in the art. Examples of processes for producingcellulose esters are taught in Kirk-Othmer, Encyclopedia of ChemicalTechnology, 5th Edition, Vol. 5, Wiley-Interscience, New York (2004),pp. 394-444, the disclosure of which is incorporated by reference in itsentirety. Cellulose, the starting material for producing celluloseesters, can be obtained in different grades and from sources such as,for example, cotton linters, softwood pulp, hardwood pulp, corn fiberand other agricultural sources, and bacterial celluloses.

One method of producing cellulose esters is by esterification. In such amethod, the cellulose is mixed with the appropriate organic acids, acidanhydrides, and catalysts and then converted to a cellulose triester.Ester hydrolysis is then performed by adding a water-acid mixture to thecellulose triester, which can be filtered to remove any gel particles orfibers. Water is added to the mixture to precipitate out the celluloseester. The cellulose ester can then be washed with water to removereaction by-products followed by dewatering and drying.

In various embodiments, the cellulose triesters that are hydrolyzed canhave three substituents selected independently from alkanoyls havingfrom 2 to 12 carbon atoms. Examples of cellulose triesters includecellulose triacetate, cellulose tripropionate, cellulose tributyrate, ormixed triesters of cellulose such as cellulose acetate propionate andcellulose acetate butyrate. These cellulose triesters can be prepared bya number of methods known to those skilled in the art. For example,cellulose triesters can be prepared by heterogeneous acylation ofcellulose in a mixture of carboxylic acid and anhydride in the presenceof a catalyst such as H₂SO₄. Cellulose triesters can also be prepared bythe homogeneous acylation of cellulose dissolved in an appropriatesolvent such as LiCl/DMAc or LiCl/NMP.

Those skilled in the art will understand that the commercial term ofcellulose triesters also encompasses cellulose esters that are notcompletely substituted with acyl groups. For example, cellulosetriacetate commercially available from Eastman Chemical Company, Inc.,Kingsport, Tenn., U.S.A., typically has a degree of substitution (“DS”)from 2.85 to 2.95.

After esterification of the cellulose to the triester, part of the acylsubstituents can be removed by hydrolysis or by alcoholysis to give asecondary cellulose ester. Secondary cellulose esters can also beprepared directly with no hydrolysis by using a limiting amount ofacylating reagent. This process is particularly useful when the reactionis conducted in a solvent that will dissolve cellulose.

The cellulose ester used in the present invention generally comprisesrepeating units of the structure:

In the above structure, R¹, R², and R³ may be selected independentlyfrom hydrogen or various acyl groups, which can include, for example, astraight chain alkanoyl having from 2 to 12 carbon atoms. In variousembodiments, the cellulose esters of the present invention can includeone or more acyl groups. For example, the cellulose esters can compriseacyl groups including aliphatic and/or aromatic C₂-C₁₂ substituents. Forinstance, the cellulose ester can be substituted with acetate,propionate, butyrate, or any aliphatic alkanoyl group having at least 2and not more than 12 carbon atoms. In certain embodiments, the celluloseester can be substituted with C₂-C₄ alkanoyl groups. For example, thecellulose ester can be substituted with acetate, propionate, butyrate,and combinations thereof.

In one or more embodiments, the cellulose ester can be a cellulosetriester or a secondary cellulose ester. Examples of cellulose triestersinclude, but are not limited to, cellulose triacetate, cellulosetripropionate, or cellulose tributyrate. Examples of secondary celluloseesters include cellulose acetate, cellulose acetate propionate, andcellulose acetate butyrate. These cellulose esters are described in U.S.Pat. No. 1,698,049; U.S. Pat. No. 1,683,347; U.S. Pat. No. 1,880,808;U.S. Pat. No. 1,880,560; U.S. Pat. No. 1,984,147; U.S. Pat. No.2,129,052; and U.S. Pat. No. 3,617,201, which are incorporated herein byreference in their entirety to the extent they do not contradict thestatements herein.

In various embodiments, the cellulose ester can be selected from thegroup consisting of cellulose acetate, cellulose acetate propionate,cellulose acetate butyrate, cellulose triacetate, cellulose diacetate,cellulose tripropionate, cellulose tributyrate, and combinationsthereof. In certain embodiments, the cellulose can be selected from thegroup consisting of cellulose acetate, cellulose acetate propionate,cellulose acetate butyrate, and combinations thereof.

In various embodiments, the cellulose ester can be a mixed celluloseester comprising at least two different acyl groups. As used herein, a“mixed cellulose ester” refers to a cellulose ester comprising at leasttwo different acyl substituents. Examples of mixed cellulose estersinclude cellulose acetate propionate and cellulose acetate butyrate. Invarious embodiments, the mixed cellulose ester comprises at least twodifferent acyl groups selected from the group consisting of acetate,propionate, butyrate, benzoate, benzoate derivatives, naphthoate,naphthoate derivatives, valerate, hexanoate, stearate, and combinationsthereof. In one or more embodiments, the mixed cellulose ester comprisesat least two different acyl groups selected from the group consisting ofacetate, propionate, butyrate, and combinations thereof. In certainembodiments, the mixed cellulose ester comprises cellulose acetatepropionate.

For cellulose esters, the substitution level is usually expressed interms of degree of substitution (“DS”), which is the average number ofsubstituents per anhydroglucose unit (“AGU”). The above formula betweenbrackets shows 2 AGU's. Generally, conventional cellulose contains threehydroxyl groups per AGU that can be substituted; therefore, the DS cantypically have a value between 0 and 3. Generally, cellulose is a largepolysaccharide with a degree of polymerization from 110 to 375 and amaximum DS of 3.0. Because DS is a statistical mean value, a value of 1does not assure that every AGU has a single substituent. In some cases,there can be unsubstituted AGU's, some AGU's with two substituents, andsome AGU's with three substituents. The DS can also refer to aparticular substituent, such as, for example, a hydroxyl group, acetate,propionate, or butyrate. For instance, a cellulose acetate can have anacetate DS of 2.0 to 2.5, with the remainder being hydroxyl groups,while a cellulose acetate propionate and cellulose acetate butyrate canhave a Total DS (i.e., combined DS of the two acyl substituents) of 1.7to 2.8, with the remainder being hydroxyl groups.

In various embodiments, the cellulose esters can have a Total DS, whichrefers to the average number of acyl substituents per AGU, of at least0.5, at least 0.7, at least 0.9, at least 1.0, at least 1.1, at least1.2, at least 1.3, at least 1.4, at least 1.5, at least 1.6, at least1.7, at least 1.8, at least 1.9, at least 2.0, at least 2.1, at least2.2, at least 2.3, at least 2.4, at least 2.5, at least 2.6, at least2.7, at least 2.8, at least 2.9, or at least 3. Additionally oralternatively, the cellulose esters can have a Total DS of not more than3.0, not more than 2.95, not more than 2.9, not more than 2.8, not morethan 2.7, not more than 2.6, not more than 2.5, not more than 2.4, notmore than 2.3, not more than 2.2, not more than 2.1, not more than 2.0,not more than 1.9, or not more than 1.8.

In various embodiments, the cellulose esters can have a DS of at least0.1, at least 0.2, at least 0.3, at least 0.4, at least 0.5, at least0.6, at least 0.7, at least 0.8, at least 0.9, at least 1.0, at least1.1, at least 1.2, at least 1.3, at least 1.4, at least 1.5, at least1.6, at least 1.7, at least 1.8, at least 1.9, at least 2.0, at least2.1, at least 2.2, at least 2.3, at least 2.4, at least 2.5, or at least2.6 for at least one acyl substituent selected from the group consistingof acetate, propionate, butyrate, benzoate, benzoate derivatives,naphthoate, naphthoate derivatives, valerate, hexanoate, stearate, andcombinations thereof. Additionally or alternatively, the celluloseesters can have a DS of not more than 3.0, not more than 2.9, not morethan 2.8, not more than 2.7, not more than 2.6, not more than 2.5, notmore than 2.0, not more than 1.8, not more than 1.6, not more than 1.5,not more than 1.4, not more than 1.3, not more than 1.2, not more than1.1, not more than 1.0, not more than 0.9, not more than 0.8, not morethan 0.7, not more than 0.6, not more than 0.5, not more than 0.4, notmore than 0.3, not more than 0.2, or not more than 0.1 for at least oneacyl substituent selected from the group consisting of acetate,propionate, butyrate, benzoate, benzoate derivatives, naphthoate,naphthoate derivatives, valerate, hexanoate, stearate, and combinationsthereof.

In various embodiments, the cellulose esters can have an acetate DS, apropionate DS and/or a butyrate DS in the same ranges as previouslydescribed for the acyl substituent.

One way to measure the hydroxyl content of the cellulose esters used inthe present invention is to measure the hydroxyl DS. The hydroxyl DS isalso one way of observing the average number of hydroxyl sites per AGUthat are not substituted. In various embodiments, the cellulose esterhas a hydroxyl DS of at least 0.005, at least 0.05, at least 0.1, atleast 0.15, at least 0.2, at least 0.25, at least 0.3, at least 0.35, orat least 0.4. Additionally or alternatively, the cellulose ester canhave a hydroxyl DS of not more than 1.3, not more than 1.2, not morethan 1.0, not more than 0.9, not more than 0.8, not more than 0.7, notmore than 0.65, not more than 0.6, not more than 0.55, not more than0.5, not more than 0.45, not more than 0.4, not more than 0.35, or notmore than 0.3.

Although not wishing to be bound by theory, it is thought that thehydroxyl content of the cellulose ester can be adjusted to increase itswettability and solubility in alcohols. The hydroxyl content can also beadjusted to enhance compatibility of the cellulose ester layer to otherlayers and sheets in the interlayers, which also contain a hydroxylcontent. Generally, in certain embodiments, the cellulose esters canhave a hydroxyl DS in the range of 0.005 to 0.5, 0.005 to 0.45, 0.005 to0.40, 0.005 to 0.35, 0.1 to 0.4, or 0.1 to 0.35.

It should be noted that any of the above DS ranges are also applicableto mixed cellulose esters. For example, a cellulose acetate propionatecould contain any of the above-referenced acetate DS ranges andpropionate DS ranges, as long as such ranges were mathematicallycompatible. Furthermore, in embodiments where the cellulose ester is amixed cellulose ester, the mixed cellulose esters can comprise a higherDS for one of the acyl substituents relative to the other acylsubstituent. For example, the cellulose esters can have a higher DS ofacetate compared to the DS of propionate.

In certain embodiments, the mixed cellulose esters can comprise acetateand a second acyl group. In such embodiments, the mixed cellulose estercan exhibit a DS ratio of the second acyl group to the acetate of atleast 0.01:1, at least 0.05:1, at least 0.1:1, at least 0.5:1, at least1:1, at least 1.5:1, at least 2:1, at least 3:1, at least 4:1, at least5:1, at least 10:1, at least 15:1, or at least 20:1. Additionally oralternatively, the mixed cellulose ester can exhibit a DS ratio of thesecond acyl group to the acetate of not more than 20:1, not more than10:1, not more than 5:1, not more than 4:1, not more than 3:1, not morethan 2:1, not more than 1:1, not more than 0.5:1, not more than 0.1:1,not more than 0.05:1, or not more than 0.01:1.

Furthermore, the cellulose esters can have a total acyl group content(“TAG”), which refers to the combination of all R acyl groups at the R¹,R², and R³ positions shown above, measured on a weight percent basis(total weight of acyl groups divided by total weight of the celluloseester) of at least 15, at least 20, at least 25, at least 30, at least35, at least 37, at least 40, or at least 45 weight percent. The upperamount is not particularly limited, and can be as high as completesubstitution of all hydroxyl groups, or up to 65, up to 60, or up 55weight percent. In various embodiments, the particular TAG content ofthe cellulose ester can depend on the type of acyl substituents bondedto the cellulose ester backbone, as well as the properties desired.

In certain embodiments, an increase in the TAG content of the celluloseester can render the cellulose ester more hydrophobic, increase itsglass transition temperature (“Tg”), and/or improve the flexibility ofthe cellulose ester. Suitable ranges of TAG content on a weight percentbasis can range from 15 to 60, 15 to 55, 20 to 60, 20 to 55, 25 to 60,25 to 55, 30 to 60, 30 to 55, 35 to 60, 35 to 55, 37 to 60, 37 to 55, 40to 60, 40 to 55, 45 to 60, or 45 to 55 weight percent. In one or moreembodiments, in order to improve interfacial compatibility with anon-cellulose ester layer and/or enhance the Tg of the cellulose esterlayer, the TAG content of the cellulose ester can generally range from30 to 60, 35 to 55, 40 to 60, or 45 to 55 weight percent.

In various embodiments, the cellulose ester can comprise at least 0.1,at least 0.5, at least 1, at least 1.5, at least 5, at least 10, atleast 15, at least 20, at least 25, at least 30, at least 35, at least40, at least 45, at least 50, at least 55, or at least 60 weight percentof at least one acyl group based on the entire weight of the celluloseester. Additionally or alternatively, the cellulose ester can comprisenot more than 80, not more than 70, or not more than 65 weight percentof at least one acyl group based on the entire weight of the celluloseester. In such embodiments, the above weight percentages may pertain toa single type of acyl substituent (e.g., acetate, propionate, benzoate,or butyrate) or to the combined weight percentage of two or more acylsubstituents (e.g., acetate and propionate) in a cellulose ester.

In various embodiments, the cellulose ester, including the mixedcellulose esters, can contain acetate on a weight percentage basis(based on the combined weight of acetate groups divided by the entirecellulose ester polymer) of at least 0.1, at least 0.5, at least 1, atleast 1.5, at least 5, at least 10, at least 15, at least 20, at least25, at least 30, at least 35, at least 40, at least 45, at least 50, atleast 55, or at least 60 weight percent. Additionally or alternatively,the cellulose ester can comprise not more than 80, not more than 70, notmore than 65, not more than 60, not more than 57, not more than 55, notmore than 52, not more than 25, not more than 20, not more than 15, notmore than 10, not more than 5, not more than 4, not more than 3, notmore than 2, or not more than 1.5 weight percent of acetate based on theentire weight of the cellulose ester.

In various embodiments, the cellulose ester, including the mixedcellulose esters, can contain propionate on a weight percentage basis(based on the combined weight of propionate groups divided by the entirecellulose ester polymer) of at least 0.1, at least 0.5, at least 1, atleast 1.5, at least 5, at least 10, at least 15, at least 20, at least25, at least 30, at least 35, at least 40, at least 45, at least 50, atleast 55, or at least 60 weight percent. Additionally or alternatively,the cellulose ester can comprise not more than 80, not more than 70, notmore than 65, not more than 60, not more than 57, not more than 55, ornot more than 52 weight percent of propionate based on the entire weightof the cellulose ester.

In various embodiments, the cellulose ester, including the mixedcellulose esters, can contain butyrate on a weight percentage basis(based on the combined weight of butyrate groups divided by the entirecellulose ester polymer) in the same ranges previously described forpropionate groups.

Furthermore, the hydroxyl content of the cellulose esters can be animportant property to consider because it can greatly affect how thecellulose ester layer will react with plasticizers and other layers inthe multilayer interlayers. In various embodiments, the cellulose ester,including the mixed cellulose esters, can contain a hydroxyl contentbased on weight percentage, which is calculated by dividing the combinedweight of all the hydroxyl groups by the weight of the entire celluloseester polymer, of at least 0.5, at least 1, at least 1.5, at least 2, atleast 2.5, at least 3, at least 3.5, at least 4, at least 4.5, at least5, at least 5.5, at least 6, at least 6.5, at least 7, at least 7.5, atleast 8, at least 8.5, at least 9, or at least 9.5 weight percent basedon the total weight of the cellulose ester. Additionally oralternatively, the cellulose ester can comprise a hydroxyl weightpercentage of not more than 30, not more than 25, not more than 20, notmore than 19, not more than 18, not more than 17, not more than 16, notmore than 15, not more than 14, not more than 13, not more than 12, notmore than 11, not more than 10 weight, not more than 8, not more than 6,not more than 4, not more than 2, not more than 1, or not more than 0.5weight percent based on the total weight of the cellulose ester.

It has been observed that cellulose esters having higher molecularweights can improve the toughness, flexibility, and impact strength ofthe cellulose ester layer. In various embodiments, the cellulose estersuseful in the present invention can have a number average molecularweight (M_(n)) of at least 12,000, at least 15,000, at least 20,000, atleast 25,000, at least 30,000, at least 35,000, at least 40,000, atleast 45,000, at least 50,000, at least 55,000, at least 60,000, atleast 65,000, or at least 70,000. Additionally or alternatively, thecellulose esters can have a number average molecular weight (M_(n)) ofup to 120,000, up to 100,000, or up to 85,000. The Mn values arepolystyrene-equivalent molecular weights determined using size exclusionchromatography.

In various embodiments, the cellulose esters can have a glass transitiontemperature (“Tg”) of at least 40° C., at least 45° C., at least 50° C.,at least 55° C., at least 60° C., at least 65° C., at least 70° C., atleast 75° C., at least 80° C., at least 85° C., at least 90° C., atleast 95° C., at least 100° C., at least 105° C., at least 110° C., atleast 115° C., at least 120° C., at least 125° C., at least 130° C., atleast 135° C., at least 140° C., or at least 145° C. Additionally oralternatively, the cellulose esters can have a Tg of not more than 250°C., not more than 240° C., not more than 230° C., not more than 220° C.,not more than 210° C., not more than 200° C., not more than 190° C., notmore than 180° C., not more than 170° C., not more than 165° C., or notmore than 160° C. Generally, the stiffness and rigidity of the celluloseester is more prominent at higher Tg levels. In such embodiments, thecellulose esters can have a Tg of at least 110° C., at least 120° C., orat least 130° C. The Tg of the cellulose ester is determined bydifferential scanning calorimetry at a 10° C./minute scan rate, secondheat scan, at the mid-point of the glass transition.

In various embodiments, the cellulose ester has a melting point of atleast 120° C., at least 130° C., at least 140° C., at least 150° C., atleast 160° C., at least 170° C., or at least 180° C. Additionally oralternatively, the cellulose ester can have a melting point of not morethan 250° C., not more than 240° C., not more than 230° C., not morethan 220° C., not more than 210° C., or not more than 200° C.

In various embodiments, the cellulose esters can exhibit a meltviscosity of at least 75,000, at least 100,000, or at least 125,000poise as measured at 170° C. and a shear rate of 1 rad/sec. Additionallyor alternatively, the cellulose esters can exhibit a melt viscosity ofnot more than 1,000,000, not more than 900,000, or not more than 800,000poise as measured at 170° C. and a shear rate of 1 rad/sec. In otherembodiments, the cellulose esters can exhibit a melt viscosity of atleast 25,000, at least 40,000, or at least 65,000 poise as measured at170° C. and a shear rate of 10 rad/sec. Additionally or alternatively,the cellulose esters can exhibit a melt viscosity of not more than400,000, not more than 300,000, or not more than 200,000 poise asmeasured at 170° C. and a shear rate of 10 rad/sec. In yet otherembodiments, the cellulose esters can exhibit a melt viscosity of atleast 10,000, at least 15,000, or at least 20,000 poise as measured at170° C. and a shear rate of 100 rad/sec. Additionally or alternatively,the cellulose esters can exhibit a melt viscosity of not more than100,000, not more than 75,000, or not more than 50,000 poise as measuredat 170° C. and a shear rate of 100 rad/sec.

The degree of polymerization (“DP”) as used herein refers to the numberof AGU's per molecule of cellulose ester. The DP is not particularlylimited, although it is desirable to employ cellulose esters having acombination of hydroxyl content and sufficiently high molecular weightto allow for film forming. In various embodiments, the cellulose esterscan have a DP of at least 110, at least 120, at least 130, at least 140,at least 150, at least 160, at least 170, at least 180, at least 190, atleast 200, at least 210, at least 220, at least 230, at least 240 and/orup to 350, up to 325, or up to 300.

Furthermore, the polydispersity of the cellulose ester is notparticularly limited. For example, the polydispersity of the celluloseester can range from 1 to 4, from 1 to 3.7, from 1.1 to 3.7, from 1.2 to3.5, or from 1.2 to 3.3, although other polydispersity ranges may beapplicable depending on the desired properties and application.

In various embodiments, the cellulose esters can have a falling ballviscosity of at least 0.005, at least 0.01, at least 0.05, at least 0.1,at least 0.5, at least 1, at least 1.5, at least 2, at least 4, at least5, at least 7, at least 10, at least 12, or at least 15 and/or up to 50,up to 45, up to 40, up to 35, up to 30, or up to 25 pascals-second(“Pas”) as measured by ASTM D817, Formula A.

In various embodiments, the cellulose esters desirably have notpreviously been subjected to fibrillation or any other fiber-producingprocess. In such embodiments, the cellulose esters are not in the formof fibrils and can be referred to as “non-fibril.”

In various embodiments, the cellulose ester can comprise aregioselectively substituted cellulose ester. Regioselectivitysubstituted cellulose esters are described in U.S. Patent ApplicationPublication No. 2010/0029927 and U.S. Pat. No. 8,729,253, thedisclosures of which are incorporated herein by reference in theirentireties. Generally, regioselectivity can be measured by determiningthe relative degree of substitution (RDS) using carbon 13 NMR. Invarious embodiments, the cellulose esters can comprise aregioselectively substituted cellulose ester that has an RDS ratio forone or more acyl substituents, for example, of C6>C2>C3, C6>C3>C2,C2>C3>C6, C3>C2>C6, C2>C6>C3, or C3>C6>C2, wherein C2, C3, and C6represent the DS of the specific acyl substituent at the R³, R², and R¹positions, respectively, on the cellulose ester structure depictedpreviously.

An exemplary cellulose ester includes a cellulose ester having a totalDS of from 2.5 to 3.0, a hydroxyl content of not more than 4 weightpercent, a propionate or butyrate DS from 2.3 to 2.95, an acetate DSfrom 0.05 to 0.4, a number average molecular weight of from 30,000 to100,000, and a Tg of at least 80° C. Another exemplary cellulose esterincludes a cellulose ester having a total DS of from 2.5 to 3.0, apropionate DS from 2.5 to 2.95, an acetate DS from 0.05 to 0.4, and anumber average molecular weight of from 40,000 to 80,000. Yet anotherexemplary cellulose ester includes a cellulose ester having a total DSof at least 2.5, a propionate or butyrate DS from 1.8 to 2.5, an acetateDS of not more than 0.35, and a hydroxyl weight percentage of 3 to 6weight percent. Still yet another exemplary cellulose ester includes acellulose ester having an acetate weight percentage of less than 4weight percent, a propionate or butyrate weight percent in the range of39 to 46 weight percent, and a hydroxyl weight percentage in the rangeof 3 to 6 weight percent.

Cellulose Ester Treatments and Modifications

In various embodiments, the cellulose esters and/or cellulose esterlayer can be modified using one or more plasticizers. As used herein,the amount of plasticizer can be measured as parts per hundred partsresin (“phr”), on a weight per weight basis. For example, if 30 grams ofplasticizer is added to 100 grams of a cellulose ester polymer, then theplasticizer content of the resulting plasticized cellulose ester wouldbe 30 phr. As used herein, when the plasticizer content of theinterlayer is given, the plasticizer content is determined withreference to the phr of the plasticizer in the corresponding celluloseester.

In various embodiments, the cellulose ester layer comprises at least 1,at least 5, at least 10, at least 15, at least 20, at least 25, at least30, at least 35, at least 40, at least 45, or at least 50 phr of atleast one plasticizer. Additionally or alternatively, the celluloseester layer can comprise not more than 100, not more than 75, not morethan 65, not more than 60, not more than 50, not more than 40, not morethan 30, not more than 20, not more than 10, not more than 5, not morethan 4, not more than 3, not more than 2, or not more than 1 phr of atleast one plasticizer. In one or more embodiments, the cellulose esterlayer comprises in the range of 1 to 75, 5 to 65, 10 to 50, or 15 to 40phr of at least one plasticizer. In certain embodiments, the celluloseester layer may not contain any plasticizers.

Because of an already high polymer glass transition temperature, one ofthe advantages of the cellulose ester layer, one of the advantages ofthe cellulose ester layer is that it can tolerate high loadings ofplasticizer while maintaining an acceptable stiffness/modulus, that is,an E′ storage modulus that is at least higher than the E′ storagemodulus of at least one other (non-cellulose ester) layer in themultilayer interlayer. Thus, high amounts of plasticizer in thecellulose ester layer are tolerable because the stiffness/modulus of thecellulose ester layer will not drop below the stiffness/modulus of theother (non-cellulose ester) layers in the multilayer interlayers.Further, the cellulose ester layer can tolerate the migration of aplasticizer from the other (non-cellulose ester) layers into thecellulose ester layer while continuing to maintain a modulus that ishigher than the modulus of the other (non-cellulose ester) layers in themultilayer interlayers. Unlike other thermoplastic polymers that are notas stiff or do not have a modulus that is as high, migration ofplasticizer into the cellulose ester layer will not affect theproperties of the cellulose ester layer to such a large extent as itmight other layers, such as a poly(vinyl acetal) layer.

In various embodiments, the cellulose esters can contain at least 2, atleast 5, at least 8, at least 10, at least 13, at least 15, at least 18,or at least 20 weight percent of at least one plasticizer based on theweight of the cellulose ester layer. Additionally or alternatively, thecellulose esters can contain up to 100, up to 80, up to 70, up to 60, upto 50, up to 40, up to 30, up to 25, or up 20 weight percent of at leastone plasticizer based on the weight of the cellulose ester layer.

The type of plasticizer used in the cellulose ester layers is notparticularly limited. The plasticizer can be any that is known in theart that can reduce the melt temperature and/or the melt viscosity ofthe cellulose ester. The plasticizer can be either monomeric orpolymeric in structure. In various embodiments, the plasticizer can be acompound having a hydrocarbon segment of 30 or less, 25 or less, 20 orless, 15 or less, 12 or less, or 10 or less carbon atoms and at least 6carbon atoms. Suitable conventional plasticizers for use in theseinterlayers include, for example, esters of a polybasic acid or apolyhydric alcohol, among others. Suitable plasticizers include, forexample, triethylene glycol di-(2-ethylhexanoate) (“3GEH”), triethyleneglycol di-(2-ethylbutyrate), triethylene glycol diheptanoate,tetraethylene glycol diheptanoate, dihexyl adipate, dioctyl adipate,hexyl cyclohexyladipate, diisononyl adipate, heptylnonyl adipate,dibutyl sebacate, butyl ricinoleate, castor oil, dibutoxy ethylphthalate, diethyl phthalate, dibutyl phthalate, trioctyl phosphate,triethyl glycol ester of coconut oil fatty acids, phenyl ethers ofpolyethylene oxide rosin derivatives, oil modified sebacic alkyd resins,tricresyl phosphate, and mixtures thereof. In certain embodiments, theplasticizer is 3GEH.

Additionally, other plasticizers, such as high refractive indexplasticizers, may also be used, either alone or in combination withanother plasticizer. As used herein, the term “high refractive indexplasticizer,” refers to a plasticizer having a refractive index of atleast 1.460. The high refractive index plasticizers may increase orreduce the refractive index of the cellulose ester layer, which mayimprove the optical properties of the interlayer, including mottle,haze, and/or clarity. In embodiments, the high RI plasticizers suitablefor use can have a refractive index of at least 1.460, at least 1.470,at least 1.480, at least 1.490, at least 1.500, at least 1.510, at least1.520 and/or not more than 1.600, not more than 1.575, or not more than1.550, measured as discussed above.

When the resin layer or interlayer includes a high RI plasticizer, theplasticizer can be present in the layer alone or it can be blended withone or more additional plasticizers. Examples of types or classes ofhigh refractive index plasticizers can include, but are not limited to,polyadipates (RI of 1.460 to 1.485); epoxides such as epoxidized soybeanoils (RI of 1.460 to 1.480); phthalates and terephthalates (RI of 1.480to 1.540); benzoates and toluates (RI of 1.480 to 1.550); and otherspecialty plasticizers (RI of 1.490 to 1.520). Specific examples ofsuitable RI plasticizers can include, but are not limited to,dipropylene glycol dibenzoate, tripropylene glycol dibenzoate,polypropylene glycol dibenzoate, isodecyl benzoate, 2-ethylhexylbenzoate, diethylene glycol benzoate, butoxyethyl benzoate,butoxyethyoxyethyl benzoate, butoxyethoxyethoxyethyl benzoate, propyleneglycol dibenzoate, 2,2,4-trimethyl-1,3-pentanediol dibenzoate,2,2,4-trimethyl-1,3-pentanediol benzoate isobutyrate, 1,3-butanedioldibenzoate, diethylene glycol di-o-toluate, triethylene glycoldi-o-toluate, dipropylene glycol di-o-toluate, 1,2-octyl dibenzoate,tri-2-ethylhexyl trimellitate, di-2-ethylhexyl terephthalate, bisphenolA bis(2-ethylhexaonate), di-(butoxyethyl) terephthalate,di-(butoxyethyoxyethyl) terephthalate, and mixtures thereof. Inembodiments, the high RI plasticizer may be selected from dipropyleneglycol dibenzoate and tripropylene glycol dibenzoate, and/or2,2,4-trimethyl-1,3-pentanediol dibenzoate. In various embodiments, theplasticizer can be selected from at least one of the following:benzoates, phthalates, phosphates, arylene-bis(diaryl phosphate), andisophthalates. In another embodiment, the plasticizer comprisesdiethylene glycol dibenzoate, abbreviated herein as “DEGDB.”

Other useful plasticizers include triphenyl phosphate, tricresylphosphate, cresyldiphenyl phosphate, octyldiphenyl phosphate,diphenylbiphenyl phosphate, trioctyl phosphate, tributyl phosphate,diethyl phthalate, dimethoxyethyl phthalate, dimethyl phthalate, dioctylphthalate, dibutyl phthalate, di-2-ethylhexyl phthalate, butylbenzylphthalate, dibenzyl phthalate, butyl phthalyl butyl glycolate, ethylphthalyl ethyl glycolate, methyl phthalyl ethyl glycolate, triethylcitrate, tri-n-butyl citrate, acetyltriethyl citrate, acetyl-tri-n-butylcitrate, and acetyl-tri-n-(2-ethylhexyl) citrate.

In various embodiments, the plasticizer can be one or more esterscomprising (i) at least one acid residue including residues of phthalicacid, adipic acid, trimellitic acid, succinic acid, benzoic acid,azelaic acid, terephthalic acid, isophthalic acid, butyric acid,glutaric acid, citric acid, and/or phosphoric acid; and (ii) alcoholresidues comprising one or more residues of an aliphatic,cycloaliphatic, or aromatic alcohol containing up to 20 carbon atoms.

Furthermore, in various embodiments, the plasticizer can comprisealcohol residues containing residues selected from the following:stearyl alcohol, lauryl alcohol, phenol, benzyl alcohol, hydroquinone,catechol, resorcinol, ethylene glycol, neopentyl glycol,1,4-cyclohexanedimethanol, and diethylene glycol.

In various embodiments, the plasticizer can comprise aliphaticpolyesters containing C₂-C₁₀ diacid residues such as, for example,malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid,suberic acid, azelaic acid, and sebacic acids.

The plasticizer can comprise diol residues which can be residues of atleast one of the following C₂-C₁₀ diols: ethylene glycol, diethyleneglycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,2-butylene glycol,1,3-butylene glycol, 1,4-butylene glycol, neopentyl glycol,1,5-pentanediol, 1,6 hexanediol, 1,5-pentylene glycol, triethyleneglycol, and tetraethylene glycol.

The plasticizer can include polyglycols, such as, for example,polyethylene glycol, polypropylene glycol, and polybutylene glycol.These can range from low molecular weight dimers and trimers to highmolecular weight oligomers and polymers.

In various embodiments, the plasticizer can comprise at least one of thefollowing plasticizers: Resoflex® R296 plasticizer, Resoflex® 804plasticizer, SHP (sorbitol hexapropionate), XPP (xylitolpentapropionate), XPA (xylitol pentaacetate), GPP (glucosepentaacetate), GPA (glucose pentapropionate), and APP (arabitolpentapropionate).

In various embodiments, the plasticizer can comprise from 5 to 95 weightpercent of a C₂-C₁₂ carbohydrate organic ester, wherein the carbohydratecomprises from 1 to 3 monosaccharide units; and from 5 to 95 weightpercent of a C₂-C₁₂ polyol ester, wherein the polyol is derived from aC₅ or C₆ carbohydrate. In one or more embodiments, the polyol ester doesnot comprise or contain a polyol acetate or polyol acetates. In variousembodiments, the plasticizer can comprise at least one carbohydrateester, wherein the carbohydrate portion of the carbohydrate ester isderived from one or more compounds selected from the group consisting ofglucose, galactose, mannose, xylose, arabinose, lactose, fructose,sorbose, sucrose, cellobiose, cellotriose, and raffinose. In variousembodiments, the plasticizer can comprise at least one carbohydrateester, wherein the carbohydrate portion of the carbohydrate estercomprises one or more of α-glucose pentaacetate, β-glucose pentaacetate,α-glucose pentapropionate, β-glucose pentapropionate, α-glucosepentabutyrate, and β-glucose pentabutyrate. In various embodiments, theplasticizer can comprise at least one carbohydrate ester, wherein thecarbohydrate portion of the carbohydrate ester comprises an α-anomer, aβ-anomer, or a mixture thereof.

In various embodiments, the plasticizer can comprise a solid stateplasticizer. In various embodiments, the plasticizer can comprise aplasticizer that enhances the fire retardation properties of thecellulose ester layer.

Furthermore, in various embodiments, the cellulose ester can be modifiedusing one or more compatibilizers. For example, the cellulose esterlayer can comprise at least 1, 2, 3, or 5 weight percent of thecompatibilizer based on the total weight of the cellulose ester layer.Additionally or alternatively, the cellulose ester layer can comprisenot more than 40, not more than 30, not more than 25, or not more than20 weight percent of the compatibilizer based on the total weight of thecellulose ester layer. In various embodiments, the compatibilizer can bea non-reactive compatibilizer. When non-reactive compatibilizers areutilized, the compatibilizer can contain a first segment that iscompatible with the cellulose ester and a second segment that iscompatible with other layers in the multilayer interlayers.

In embodiments where the compatibilizer is a non-reactivecompatibilizer, the first segment may contain polar functional groups,which provide compatibility with the cellulose ester, including, but notlimited to, such polar functional groups as ethers, esters, amides,alcohols, amines, ketones, and acetals. The first segment may includeoligomers or polymers of the following: cellulose ethers;polyoxyalkylene, such as, polyoxyethylene, polyoxypropylene, andpolyoxybutylene; polyglycols, such as, polyethylene glycol,polypropylene glycol, and polybutylene glycol; polyesters, such as,polycaprolactone, polylactic acid, aliphatic polyesters, andaliphatic-aromatic copolyesters; polyacrylates and polymethacrylates;polyacetals; polyvinylpyrrolidone; polyvinyl acetate; and polyvinylalcohol. In one or more embodiments, the first segment ispolyoxyethylene or polyvinyl alcohol. The second segment can becompatible with the other layers in the multilayer interlayers andcontain nonpolar groups. The second segment can contain saturated and/orunsaturated hydrocarbon groups. In one or more embodiments, the secondsegment can be an oligomer or a polymer. In other embodiments, thesecond segment of the non-reactive compatibilizer is selected from thegroup consisting of polyolefins, polydienes, polyaromatics, andcopolymers. In one or more embodiments, the first and second segments ofthe non-reactive compatibilizers can be in a diblock, triblock,branched, or comb structure. In such embodiments, the molecular weightof the non-reactive compatibilizers can range from 300 to 20,000, 500 to10,000, or 1,000 to 5,000. The segment ratio of the non-reactivecompatibilizers can range from 15 to 85 percent polar first segments to15 to 85 percent nonpolar second segments.

Examples of non-reactive compatibilizers include, but are not limitedto, ethoxylated alcohols, ethoxylated alkylphenols, ethoxylated fattyacids, block polymers of propylene oxide and ethylene oxide,polyglycerol esters, polysaccharide esters, and sorbitan esters.Examples of ethoxylated alcohols are C₁₁-C₁₅ secondary alcoholethoxylates, polyoxyethylene cetyl ether, polyoxyethylene stearyl ether,and C₁₂-C₁₄ natural liner alcohol ethoxylated with ethylene oxide.C₁₁-C₁₅ secondary ethyoxylates can be obtained as Dow Tergitol® 15S(from the Dow Chemical Company). Polyoxyethylene cetyl ether andpolyoxyethylene stearyl ether can be obtained under the Brij® series ofproducts (from ICI Surfactants). C₁₂-C₁₄ natural linear alcoholethoxylated with ethylene oxide can be obtained under the Genapol®series of products (from Hoechst Celanese). Examples of ethoxylatedalkylphenols include octylphenoxy poly(ethyleneoxy)ethanol andnonylphenoxy poly(ethyleneoxy)ethanol. Octylphenoxypoly(ethyleneoxy)ethanol can be obtained as Igepal® CA series ofproducts (from Rhodia), and nonylphenoxy poly(ethyleneoxy)ethanol can beobtained as Igepal® CO series of products (from Rhodia) or as Tergitol®NP (from Dow Chemical Company). Ethyoxylated fatty acids includepolyethyleneglycol monostearate or monolaurate which can be obtainedunder the Nopalcol® series of products (from Henkel). Block polymers ofpropylene oxide and ethylene oxide can be obtained under the Pluronic®series of products (from BASF). Polyglycerol esters can be obtainedunder the Drewpol® series of products (from Stepan). Polysaccharideesters can be obtained under the Glucopon® series of products (fromHenkel), which are alkyl polyglucosides. Sorbitan esters can be obtainedunder the Tween® series of products (from ICI).

In various embodiments, the compatibilizer can be a reactivecompatibilizer. The reactive compatibilizer comprises a polymer oroligomer compatible with one component of the cellulose ester andfunctionality capable of reacting with another component of anotherlayer of the multilayer interlayer. Generally, there are two types ofreactive compatibilizers. The first reactive compatibilizer can have ahydrocarbon chain that is compatible with nonpolar segments of the otherlayers in the multilayer interlayers and also have functionality capableof reacting with the cellulose ester. Such functional groups include,but are not limited to, carboxylic acids, anhydrides, acid chlorides,epoxides, and isocyanates. Specific examples of this type of reactivecompatibilizer include, but are not limited to: long chain fatty acids,such as stearic acid (octadecanoic acid); long chain fatty acidchlorides, such as stearoyl chloride (octadecanoyl chloride); long chainfatty acid anhydrides, such as stearic anhydride (octadecanoicanhydride); epoxidized oils and fatty esters; styrene maleic anhydridecopolymers; maleic anhydride grafted polypropylene; copolymers of maleicanhydride with olefins and/or acrylic esters, such as terpolymers ofethylene, acrylic ester and maleic anhydride; and copolymers of glycidylmethacrylate with olefins and/or acrylic esters, such as terpolymers ofethylene, acrylic ester, and glycidyl methacrylate.

Examples of reactive compatibilizers include SMA® 3000 styrene maleicanhydride copolymer (from Sartomer/Cray Valley), Eastman G-3015® maleicanhydride grafted polypropylene (from Eastman Chemical Company),Epolene® E-43 maleic anhydride grafted polypropylene (from WestlakeChemical), Lotader® MAH 8200 random terpolymer of ethylene, acrylicester, and maleic anhydride, Lotader® GMA AX 8900 random terpolymer ofethylene, acrylic ester, and glycidyl methacrylate, and Lotader® GMA AX8840 random terpolymer of ethylene, acrylic ester, and glycidylmethacrylate (from Arkema).

In various embodiments, the cellulose ester and/or cellulose ester layercan be treated or modified with a boron atom containing compound, suchas boric acid or a borate. Although not wishing not to be bound bytheory, it is believed that modifying or treating the cellulose estersor cellulose ester layer with boron atom containing material, such asboric acid and/or borate, will enhance the adhesion between thecellulose ester layer and other non-cellulose ester layers in themultilayer interlayer, such as polyvinyl butyral layers. The use ofboron treatments on interlayers is further described in U.S. PatentApplication Publication No. 2012/0204940, which is incorporated hereinby reference in its entirety.

In various embodiments, boron atom containing compounds, such as boricacid and/or borate, can be added to the cellulose ester prior to formingthe cellulose ester layer. For example, boron atom containing compoundcan be combined with the cellulose ester to form an initial mixture,which can then be formed into the sheet forming the cellulose esterlayer. In such embodiments, the boron atom containing compound can beco-extruded with the cellulose ester when forming the cellulose esterlayer.

In one or more embodiments, the boric acid can comprise boric acid,metaboric acid, or mixtures thereof. In other embodiments, the boratecan comprise boric anhydrides, boron oxides, triethanol amine borate(boratranes), metal borates, or a combination thereof. In certainembodiments, the borate comprises an alkali metal borate or boratrane,or borate ester such as tri-n-butyl borate or tri-n-propyl borate.

The addition of boron atom containing compounds, such as boric acid, tocellulose esters and blends thereof with different molecular weightshelps to achieve a desired extrusion melt viscosity with a desired boronlevel or microequivalents boron/g also helps to improve adhesion. Thisboth aides with adhesion to other polymers such as polyvinyl butyral,either in films or blends, as well as to couple the cellulose esterpolymer matrix to additives, such as silica particles which are known tohave residual hydroxyl content as silanols on their surfaces. Forexample, melt viscosity of cellulose esters, such as cellulose acetatepropionate (“CAP”), and blends thereof with different molecular weightscan be increased by the addition of borates, which crosslink with thehydroxyl groups in CAP, thus raising the melt viscosity. As an example,adding 0.5 phr of boric acid to a low molecular weight CAP material (CAP482-0.5, M_(n) 25,000 g/mol) having 20% 3GEH plasticizer increases theviscosity of the CAP to 74,176 Pa-sec (dynamic viscosity at 190° C.,0.063 rad/sec), which is about a 25-fold increase over a CAP materialhaving a much higher initial molecular weight (CAP 482-20, M_(n) 75,000g/mol, dynamic viscosity of 5,013 Pa-sec at 190° C., 0.063 rad/sec) withthe same 20% 3GEH plasticizer but without the addition of the boricacid. Adding 0.2 phr boric acid to the higher molecular weight CAP (CAP482-20 with and 20% 3GEH plasticizer) increased the melt viscosity to110,541 Pa-sec (dynamic viscosity at 190° C., 0.63 rad/sec). This highmelt viscosity creates a high pressure drop that makes extrusiondifficult without much higher extrusion melt temperatures, therefore theability to increase the viscosity of the lower molecular weight CAP canbe beneficial.

In various embodiments, the cellulose ester layer comprises at least0.001, at least 0.005, at least 0.01, at least 0.05, at least 0.1, atleast 0.5, at least 1, at least 2, at least 3, at least 4, at least 5,at least 6, at least 7, at least 8, at least 9, at least 10, at least15, or at least 20 weight percent of the boron atom containing compound(such as boric acid and/or borate) based on the total weight of thecellulose ester layer. Additionally or alternatively, the celluloseester layer can comprise not more than 75, not more than 60, not morethan 50, not more than 40, not more than 30, not more than 25, not morethan 20, not more than 15, not more than 10, not more than 5, or notmore than 2 weight percent of the boron atom containing compound basedon the total weight of the cellulose ester layer.

In some embodiments, the cellulose ester layer comprises at least 0.001,at least 0.005, at least 0.01, at least 0.05, at least 0.1, at least0.5, at least 1, at least 2, at least 3, at least 4, at least 5, atleast 6, at least 7, at least 8, at least 9, at least 10, at least 15,or at least 20 phr of the boron atom containing compound. Additionallyor alternatively, the cellulose ester layer can comprise not more than75, not more than 50, not more than 30, not more than 20, not more than15, not more than 10, not more than 5 phr, not more than 1 phr, or notmore than 0.7 phr of boron atom containing compound.

In other embodiments, the cellulose ester layer comprises at least 1, atleast 5, at least 10, at least 15, or at least 20 micro equivalents ofboron atom containing compound per gram of cellulose ester resin.Additionally or alternatively, the cellulose ester layer can comprisenot more than 500, not more than 400, not more than 300, not more than200, not more than 150, not more than 130, or not more than 115 microequivalents of boron atom containing compound per gram of celluloseester resin, where one micro equivalent is 10⁻⁶ mole boron/gram ofcellulose ester resin.

Furthermore, in certain embodiments, the cellulose ester or celluloseester layer may be modified with an antioxidant. Although not wishingnot to be bound by theory, it is believed that modifying or treating thecellulose esters or cellulose ester layer with an antioxidant willenhance the adhesion between the cellulose ester layer and other layersin the multilayer interlayer, such as polyvinyl butyral layers. Theantioxidant can include, for example, phenolic antioxidants such assterically hindered alkylated bisphenol. Commercial examples of suchantioxidants include, for example, Lowinox® 44B325 (from Addivant).

Furthermore, in various embodiments, the cellulose esters or thecellulose ester layers can be subjected to plasma treatment, coronatreatment and/or flame treatment. Although not wishing to be bound bytheory, it is believed that the plasma treatment, corona treatmentand/or flame treatment will enhance the bonding between the celluloseester layer and the other layers in a multilayer interlayer. Plasmatreatment is a known technique to those skilled in the art to increaseadhesion between different polymer layers.

In various embodiments, the cellulose ester layers can comprise asaponified cellulose ester. Although not wishing to be bound by theory,it is believed that the saponified cellulose ester will enhance thebonding between the cellulose ester layer and the other layers in amultilayer interlayer. Saponification with aqueous sodium hydroxide canbe carried out to produce a layer of cellulose on one or both surfacesof the cellulose ester interlayer surface, and this layer candramatically improve the interfacial adhesion between the non-celluloseester layer (such as polyvinyl butyral and the cellulose ester).Improvement from less than 4 MPa to greater than 10 MPa in compressionshear can be achieved without affecting optical properties such asyellowness or haze of the composite multilayer interlayer.Alternatively, a discrete thin film or layer of cellulose can be used asa tie layer between a non-cellulose ester layer and a cellulose esterlayer. Saponification is known in the art, and can be as disclosed, forexample, in Japanese Patent 07062120.

In various embodiments, the cellulose ester may be modified with amaleic anhydride. In such embodiments, cellulose ester and maleicanhydride can be combined prior to forming the cellulose ester layers.For example, the cellulose ester and maleic anhydride can be mixed andco-extruded to produce the cellulose ester layer. Additionally oralternatively, a maleic anhydride coating may be applied onto thecellulose ester layer. In such embodiments, the maleic anhydride coatingmay be applied to the cellulose ester layer using any method known inthe art including, for example, dip coating, spray coating, gravurecoating, or inkjet printing. Although not wishing to be bound by theory,it is believed that the maleic anhydride will enhance the bondingbetween the cellulose ester layer and the other layers in the multilayerinterlayers. In various embodiments, the cellulose ester layer comprisesat least 0.01, at least 0.1, at least 0.5, at least 1, at least 2, atleast 3, at least 4, at least 5, at least 6, at least 7, at least 8, atleast 9, at least 10, at least 15, or at least 20 and not more than 75,not more than 60, not more than 50, not more than 40, not more than 30,not more than 25, not more than 20, not more than 15, not more than 10,not more than 5, or not more than 2 weight percent of the maleicanhydride based on the total weight of the layer. In one or moreembodiments, the maleic anhydride is selected from the group consistingof styrene maleic anhydride copolymers, maleic anhydride graftedpolypropylene, copolymers of maleic anhydride with olefins and/oracrylic esters, and combinations thereof.

Cellulose Ester Blends

In various embodiments, the cellulose ester layers described herein canbe used to form a “monolithic sheet” or a “monolithic interlayer.” Incertain embodiments, the monolithic interlayer or sheet can contain apolymer blend comprising a cellulose ester and at least one otherthermoplastic polymer. Alternatively, these polymer blends can be usedto form cellulose ester layers that are capable of better adhering toother layers in a multilayer interlayer including, for example,polyvinyl butyral layers.

As used herein, a “polymer blend” refers to the combination of at leasttwo different species of polymers without limitation on the method fortheir combination. Generally, a polymer blend is in a solid state unlessotherwise expressed as a molten polymer blend. Without limitation, thepolymer blend can be an immiscible polymer blend in which the monolithicinterlayer will exhibit two glass transition peaks. Alternatively, thepolymer blend can be a miscible or homogeneous polymer blend in whichthe monolithic interlayer will either exhibit one glass transition peak,or appear as a compatible polymer blend on a macroscale that exhibitsuniform physical properties.

In various embodiments, a polymer blend can form a polymer-polymercomplex in which a molecular entity can be formed from the two polymersand such molecular entity can be ionic or uncharged. A polymer blend mayor may not form an interpenetrating or semi-interpenetrating polymernetwork, or form a polymer composite in which at least one of thepolymers forms a continuous phase while the other polymer forms adiscontinuous phase.

In various embodiments, the cellulose ester layer comprises a polymerblend containing at least one cellulose ester and at least onethermoplastic polymer. The thermoplastic polymer can be selected fromthe group consisting of ethylene vinyl acetate, thermoplasticpolyurethane, ionomer, poly(vinyl acetal), and combinations thereof.

In various embodiments, the cellulose ester layer containing the polymerblend can comprise at least 1, at least 5, at least 10, at least 15, atleast 20, at least 25, at least 30, at least 35, at least 40, at least45, at least 50, at least 55, at least 60, at least 65, at least 70, atleast 75, at least 80, at least 85, at least 90, at least 95, or atleast 99 weight percent of the cellulose ester based on the total weightof the layer. Additionally or alternatively, the cellulose ester layercontaining the polymer blend can comprise not more than 99, not morethan 95, not more than 90, not more than 85, not more than 80, not morethan 75, not more than 70, not more than 65, not more than 60, not morethan 55, not more than 50, not more than 45, not more than 40, not morethan 35, not more than 30, not more than 25, not more than 20, not morethan 15, not more than 10, not more than 5, or not more than 1 weightpercent of the cellulose ester based on the total weight of the layer.

In various embodiments, the cellulose ester layer containing the polymerblend can comprise at least 1, at least 5, at least 10, at least 15, atleast 20, at least 25, at least 30, at least 35, at least 40, at least45, at least 50, at least 55, at least 60, at least 65, at least 70, atleast 75, at least 80, at least 85, at least 90, at least 95, or atleast 99 weight percent of the thermoplastic polymer based on the totalweight of the layer. Additionally or alternatively, the cellulose esterlayer containing the polymer blend can comprise not more than 99, notmore than 95, not more than 90, not more than 85, not more than 80, notmore than 75, not more than 70, not more than 65, not more than 60, notmore than 55, not more than 50, not more than 45, not more than 40, notmore than 35, not more than 30, not more than 25, not more than 20, notmore than 15, not more than 10, not more than 5, or not more than 1weight percent of the thermoplastic polymer based on the total weight ofthe layer. The particular amount of cellulose ester and the amount ofthermoplastic polymer in the polymer blend and the cellulose ester layeris dependent upon the desired characteristics and types of celluloseesters and thermoplastic polymer resins chosen. In various embodiments,the cellulose ester layers described herein can comprise, consistessentially of, or consist of the polymer blend.

In one or more embodiments, the thermoplastic polymer comprises athermoplastic polyurethane. In certain embodiments, the thermoplasticpolyurethane can comprise an aliphatic polyurethane. In otherembodiments, the thermoplastic polymer comprises an ethylene vinylacetate. In certain embodiments, the ethylene vinyl acetate comprises avinyl acetate content of at least 70, at least 80, or at least 90 and/ornot more than 99, not more than 98, or not more than 95 weight percent.It has been observed that ethylene vinyl acetate polymers having highervinyl acetate contents can be more miscible with cellulose ester whenforming layers and/or blends. In other embodiments, the ethylene vinylacetate comprises a vinyl acetate content of at least 20, at least 25,at least 30, at least 35 and/or not more than 40, not more than 35, ornot more than 30 weight percent. In yet other embodiments, thethermoplastic polymer comprises an ionomer. In one or more embodiments,the ionomer resin comprises partially neutralized acid-ethylenecopolymers. In other embodiments, the thermoplastic polymer comprises apoly(vinyl acetal) such as polyvinyl butyral. The various thermoplasticpolymers are discussed in more detail below.

The cellulose ester can be either plasticized or unplasticized when usedto produce the polymer blends. In one or more embodiments, the celluloseester layer containing the polymer blend can comprise less than 10, lessthan 5, less than 4, less than 3, less than 2, or less than 1 phr of aplasticizer. In certain embodiments, the cellulose ester layercontaining the polymer blend does not contain any added plasticizers.When used, the plasticizers utilized in the polymer blends can includeany of the previously described plasticizers.

In various embodiments, the polymer blend can form a monolithicinterlayer having a higher stiffness than an interlayer made only withthe thermoplastic polymer resin. The monolithic interlayers can havegood optical clarity when laminated between glass.

Furthermore, the cellulose esters can provide a dual functionality whenblended with the thermoplastic polymer resins. For instance, thecellulose esters can act as a processing aid since they can melt andflow at common extrusion temperatures, thereby breaking down intosmaller particles and reducing the viscosity of the thermoplasticpolymer resins during processing. After being dispersed throughout thethermoplastic polymer resins, the cellulose esters can re-solidify uponcooling and can act as a reinforcing filler that strengthens thethermoplastic polymer resin.

It is believed that the cellulose esters in the polymer blends canenable the production of an interlayer that exhibits improved viscosityduring processing over using solid fillers, to provide enhanced modulusand stiffness, yet simultaneously provide the necessary optical clarityrequired in many laminated glass or multiple layer panel applications.

The cellulose ester layers comprising the polymer blend can be producedby two different types of processes. The first process involves directlymelt dispersing the cellulose ester and the thermoplastic polymer resin.The second process involves mixing a cellulose ester with a carrierthermoplastic polymer resin to produce a cellulose ester concentrate andthen blending the cellulose ester concentrate with the thermoplastic toform the polymer blend.

In the first process, the cellulose ester can be blended directly with athermoplastic polymer resin to produce a polymer blend composition thatis either a molten polymer blend or a solid polymer blend. The firstprocess generally comprises combining at least one solid thermoplasticpolymer resin, at least one solid cellulose ester, and, optionally, oneor more additives such as adhesion control agents (“ACAs”),compatibilizers, UV stabilizers, or any other additive mentioned above,to make a solid/solid blend, mixing the solid/solid blend, and heatingthe solid/solid blend for a sufficient time and at a temperature to makea molten polymer blend or a softened polymer blend.

The second process generally comprises melting a solid thermoplasticpolymer resin and melting or softening a cellulose ester resin, followedby combining and mixing the molten thermoplastic polymer resin with themelted or softened cellulose ester resin for a time and a temperaturesufficient to make a molten blend. As used throughout, a molten blendcan have solid or softened particulates so long as at least a moltenphase is present.

In the second process, the cellulose ester is first mixed with a carrierthermoplastic polymer resin to produce a cellulose ester concentrate(i.e., a cellulose ester masterbatch), which can subsequently be blendedwith a thermoplastic polymer resin to produce a molten or solid polymerblend. This second process may also be referred to as the “masterbatchprocess.” One advantage of this masterbatch process is that it can morereadily disperse cellulose esters having a higher Tg throughout thethermoplastic polymer resin. In one or more embodiments, the masterbatchprocess involves mixing a high Tg cellulose ester with a compatiblecarrier thermoplastic polymer resin to produce a cellulose esterconcentrate, and then blending the cellulose ester concentrate with atleast one thermoplastic polymer resin to produce a molten or solidpolymer blend. The masterbatch has a higher concentration by weight ofcellulose ester than the concentration of cellulose ester in a molten orsolid polymer blend or in an interlayer or sheet.

In various embodiments, the cellulose ester concentrate can comprise atleast 10, at least 15, at least 20, at least 25, at least 30, at least35, or at least 40 weight percent of cellulose ester based on the weightof the concentrate. Additionally or alternatively, the cellulose esterconcentrate can comprise not more than 90, not more than 85, not morethan 80, not more than 75, not more than 70, not more than 65, not morethan 60, not more than 55, or not more than 50 weight percent ofcellulose ester, based on the weight of the concentrate.

The thermoplastic polymer resin, cellulose ester, fillers, and additivescan be added or combined in any order during the above processes. Solidthermoplastic polymer resin particles and solid cellulose esterparticles can be combined and fed together as a single stream to a melttank and melted, optionally under mechanical agitation or shear, withthe melt then fed to an extrusion device. Alternatively, the combinedthermoplastic polymer resin and cellulose ester particles can be fed asa single stream into an extrusion device. In another method, thethermoplastic polymer resin and cellulose ester particles can be fed asindividual streams to an extrusion device. The thermoplastic polymerresin and/or cellulose ester can be modified with a plasticizer and/orcompatibilizer prior to being blended together.

A sufficient temperature for mixing the cellulose ester and thethermoplastic polymer resins can be the flow temperature of thecellulose ester, which can be at least 10° C., at least 15° C., at least20° C., at least 25° C., at least 30° C., at least 35° C., at least 40°C., at least 45° C., or at least 50° C. above the Tg of the celluloseester. At least a portion of the melt temperature, optionally undershear, can occur at a temperature of at least 100° C., at least 120° C.,at least 140° C., at least 150° C., at least 160° C., at least 180° C.,at least 200° C., at least 220° C., at least 230° C., at least 235° C.,or at least 240° C. and/or up to 280° C., up to 260° C., up to 255° C.,up to 250° C., up to 245° C., up to 240° C., up to 230° C., up to 220°C., or up to 210° C. The set temperature of a die through which themolten polymer blend flows is desirably at least 170° C., or at least180° C. and/or up to 245° C., up to 240° C., up to 230° C., or up to220° C. The temperature of the blending can be limited by thethermoplastic polymer resin's upper processing temperature range and thelower processing temperature range of the cellulose ester.

In certain embodiments, at least a portion of the blending of thecellulose ester and the thermoplastic polymer resin occurs at atemperature that will not degrade the thermoplastic polymer resin. Forinstance, at least a portion of the blending can occur at a temperatureof not more than 250° C., not more than 200° C., not more than 180° C.,not more than 170° C., not more than 160° C., or not more than 150° C.

During both of the processes described above, the cellulose esters caneffectively soften and/or melt, thus allowing the cellulose esters toform into sufficiently small particle sizes under the specified blendingconditions. In such embodiments, due to the small particle sizes, thecellulose esters can be thoroughly dispersed throughout thethermoplastic polymer resin during the process. In one or moreembodiments, the domains of the cellulose ester in the cellulose esterlayer can have a spherical or near-spherical shape. As used herein, a“near-spherical” shape is understood to include particles having across-sectional aspect ratio of less than 2:1. In more particularembodiments, the spherical and near-spherical domains have across-sectional aspect ratio of less than 1.5:1, less than 1.2:1, orless than 1.1:1. The “cross-sectional aspect ratio” as used hereinrefers to the ratio of the longest dimension of the particle'scross-section relative to its shortest dimension. In furtherembodiments, at least 75, at least 80, at least 85, at least 90, atleast 95, or at least 99.9 percent of the domains of cellulose esters inthe polymer blend have a cross-sectional aspect ratio of not more than10:1, not more than 8:1, not more than 6:1, or not more than 4:1.

In various embodiments, at least 75, at least 80, at least 85, at least90, at least 95, or at least 99.9 weight percent of the cellulose estercan have a diameter of not more than 10, not more than 8, not more than5, not more than 4, not more than 3, not more than 2, or not more than 1μm subsequent to melt blending the cellulose ester with thethermoplastic polymer resin.

The cellulose esters added at the beginning of the process can be in theform of a powder having particle sizes ranging from 200 to 400 μm.Subsequent to blending the cellulose ester with the thermoplasticpolymer resin, the cellulose ester domain size can decrease by at least50, at least 75, at least 90, at least 95, or at least 99 percentrelative to their particle size prior to blending.

In various embodiments, the cellulose ester layer can be characterizedas a disperse phase of cellulose ester in a continuous phase of thethermoplastic polymer resin. Alternatively, the cellulose ester layercan be characterized as a disperse phase of thermoplastic polymer resinin a continuous phase of the thermoplastic polymer resin.

In embodiments wherein the cellulose ester layers comprise a polymerblend having two or more Tg peaks, the Tg of the other thermoplasticpolymer resin can be at least −20° C., at least 0° C., at least 10° C.,at least 20° C., at least 30° C., at least 40° C., at least 45° C., atleast 50° C., at least 60° C., at least 65° C., at least 70° C., atleast 75° C., at least 80° C., at least 85° C., at least 90° C., atleast 95° C., at least 100° C., at least 110° C., at least 120° C., atleast 130° C. less than the Tg of the cellulose ester.

The melt viscosity ratio of the cellulose ester to the thermoplasticpolymer resin can be at least 0.1, at least 0.2, at least 0.3, at least0.5, at least 0.8, or at least 1.0 as measured at 170° C. and a shearrate of 400 s⁻¹. Additionally or alternatively, the melt viscosity ratioof the cellulose ester to the thermoplastic polymer resin can be no morethan 2, no more than 1.8, no more than 1.6, no more than 1.4, or no morethan 1.2 as measured at 170° C. and a shear rate of 400 s⁻¹. The meltviscosity ratio of the cellulose ester to the thermoplastic polymerresin can be at least 0.1, at least 0.2, at least 0.3, at least 0.5, atleast 0.8, or at least 1.0 as measured at 160° C. and a shear rate of200 s⁻¹. Additionally or alternatively, the melt viscosity ratio of thecellulose ester to the thermoplastic polymer resin can be no more than2, no more than 1.8, no more than 1.6, no more than 1.4, or no more than1.2 as measured at 160° C. and a shear rate of 200 s⁻¹. The mixing andblending of the aforementioned processes can be accomplished by anyblending methods known in the art. Examples of mixing equipment include,but are not limited to, Banbury mixers, Brabender mixers, roll mills,planetary mixers, single screw extruders, and twin screw extruders. Theshear energy during the mixing is dependent on the combination ofequipment, blade design, rotation speed (rpm), and mixing time. Theshear energy should be sufficient for breaking down softened/meltedcellulose esters to a small enough size to disperse the cellulose estersthroughout the thermoplastic polymer resin. For example, when a Banburymixer is utilized, the shear energy and time of mixing can range from 5to 15 minutes at 100 rpms. In certain embodiments of the presentinvention, at least a portion of the blending and/or mixing stagesdiscussed above can be carried out at a shear rate of at least 50, atleast 75, at least 100, at least 125, or at least 150 s⁻¹. Additionallyor alternatively, at least a portion of the blending and/or mixingstages discussed above can be carried out at a shear rate of not morethan 1,000, not more than 900, not more than 800, not more than 600, ornot more than 550 s⁻¹.

It is known in the art that the efficiency of mixing two or moreviscoelastic materials can depend on the ratio of the viscosities of theviscoelastic materials. For a given mixing equipment and shear raterange, the viscosity ratio of the dispersed phase (e.g., celluloseester) and continuous phase (e.g., thermoplastic polymer resin) shouldbe within specified limits for obtaining adequate particle size. Invarious embodiments where low shear rotational shearing equipment isutilized, such as, Banbury and Brabender mixers, the viscosity ratio ofthe dispersed phase (e.g., cellulose esters) to the continuous phase(e.g., thermoplastic polymer resin) can range from 0.001 to 5, from 0.01to 5, and from 0.1 to 3. In yet another embodiment of the inventionwhere high shear rotational/extensional shearing equipment is utilized,such as, twin screw extruders, the viscosity ratio of the dispersedphase (e.g., cellulose ester) to the continuous phase (e.g.,thermoplastic polymer resin) can range from 0.001 to 500 and from 0.01to 100.

It is also known in the art that when mixing two or more viscoelasticmaterials, the difference between the interfacial energy of the twoviscoelastic materials can affect the efficiency of mixing. Mixing canbe more efficient when the difference in the interfacial energy betweenthe materials is minimal. In various embodiments, the surface tensiondifference between the dispersed phase of cellulose ester and continuousthermoplastic polymer resin phase is less than 100 dynes/cm, less than50 dynes/cm, or less than 20 dynes/cm.

Where optical clarity is desired, a means for achieving good opticalclarity is to ensure that the delta RI value (the absolute value of thedifference between the refractive index of the cellulose ester and therefractive index of the thermoplastic polymer resin, inclusive of anyplasticizer contained in each) between the cellulose ester and thethermoplastic polymer resin is small. Thus, the delta RI is desirablynot more than 0.014, not more than 0.012, not more than 0.010, not morethan 0.009, not more than 0.007, not more than 0.006, not more than0.005, or not more than 0.004. Delta RI values of not more than 0.007provide an excellent optical clarity. Thus, where optical clarity isneeded in the desired application, the cellulose ester and the selectedthermoplastic polymer resin should each have refractive indices thatclosely match each other (that is, having a delta RI as close to 0 aspossible) as noted by the small delta RI values mentioned above. Therefractive index can be measured according to ASTM D542 at a wavelengthof 589 nm and 25° C. or by transferring 0.4 mL of liquid to the prismsurface of an ATAGO RX-7000 (alpha) automatic digital refractometer. Thesample should be bubble free for accurate results. The prism is cleanedwith acetone between samples.

Properties of the Cellulose Ester Layers

In various embodiments, the cellulose ester layers described herein cancomprise, consist essentially of, or consist of at least one of thepreviously described cellulose esters. Generally, the cellulose esterlayers can comprise at least 1, at least 2, at least 3, at least 4, atleast 5, at least 10, at least 15, at least 20, at least 25, at least30, at least 35, at least 40, at least 45, at least 50, at least 55, atleast 60, at least 65, at least 70, at least 75, at least 80, at least85, at least 90, at least 95, or at least 99 weight percent of one ormore cellulose esters based on the total weight of the cellulose esterlayer. Additionally or alternatively, the cellulose ester layers cancomprise not more than 99, not more than 95, not more than 90, not morethan 80, not more than 70, not more than 60, or not more than 50 weightpercent of one or more cellulose esters based on the total weight of thecellulose ester layer.

As discussed above, the cellulose ester layers described herein canprovide load bearing support to a structural interlayer based on itsrigidity and stiffness. For example, the cellulose ester layer canexhibit a shear storage modulus at a temperature below the Tg of thecellulose ester that is higher than the shear storage modulus ofnon-cellulose materials (thermoplastic materials such as poly(vinylbutyral, polyurethane, EVA, ionomer and the like). In embodiments, theshear storage modulus at a temperature below the Tg of the celluloseester may be at least 1.00E+06, at least 1.00E+07, or at least 1.00E+08Pa as measured according to ASTM D4065-12.

The cellulose ester layers can have varying thicknesses, which arelargely determined by the type of interlayer or laminate that the layeris being used in. In various embodiments, the cellulose ester layer canhave a thickness of at least 1 mil, at least 5 mils, at least 10 mils,at least 11 mils, at least 12 mils, at least 13 mils, at least 14 mils,at least 15 mils, at least 16 mils, at least 17 mils, at least 18 mils,at least 19 mils, at least 20 mils, at least 21 mils, at least 22 mils,at least 23 mils, at least 24 mils, or at least 25 mils. Additionally oralternatively, the cellulose ester layer can have a thickness of up to2,000 mils, up to 1,000 mils, up to 500 mils, up to 100 mils, up to 80mils, up to 50 mils, up to 45 mils, up to 40 mils, up to 35 mils, or upto 30 mils. Other thicknesses may be appropriate depending on thedesired properties.

Non-Cellulose Ester Layers

As noted above, the cellulose ester layers described herein can be usedwith various types of non-cellulose ester layers to form multilayerinterlayers and structural laminates. As used herein, a “non-celluloseester layer” refers to a separate layer or sheet that does not contain acellulose ester. In various embodiments, these non-cellulose esterlayers can be formed from a thermoplastic resin selected from the groupconsisting of ethylene vinyl acetate, thermoplastic polyurethane,ionomer, poly(vinyl acetal), and mixtures thereof. The variousconfigurations and types of non-cellulose ester layers are described indetail below.

The use of a non-cellulose ester layer(s) in combination with acellulose ester(s) can provide beneficial properties to a multilayerinterlayer. For example, multiple layer interlayers comprising multiplepoly(vinyl acetal) resins and layers having different properties andplasticizer levels sometimes experience plasticizer partitioning betweenthe layers as the interlayer equilibrates. When a cellulose esterlayer(s) is used, depending on the combination of layers and structure,even if plasticizer partitions or moves to the cellulose ester layer,the modulus of the cellulose ester layer remains higher than that of theother, non-cellulose ester layer because the cellulose ester layerretains higher glass transition temperature even after plasticizer movesto it.

Generally, the non-cellulose ester layers can comprise at least 1, atleast 2, at least 3, at least 4, at least 5, at least 10, at least 15,at least 20, at least 25, at least 30, at least 35, at least 40, atleast 45, at least 50, at least 55, at least 60, at least 65, at least70, at least 75, at least 80, at least 85, at least 90, at least 95, orat least 99 weight percent of one or more thermoplastic resins based onthe total weight of the non-cellulose ester layer. Additionally oralternatively, the non-cellulose ester layers can comprise not more than99, not more than 95, not more than 90, not more than 80, not more than70, not more than 60, or not more than 50 weight percent of one or morethermoplastic resins based on the total weight of the non-celluloseester layer. The types of non-cellulose ester layers and thermoplasticresins that can be used to produce such layers are described furtherbelow.

In various embodiments, the non-cellulose ester and cellulose esterlayers can be in direct contact with each other or can be indirectlydisposed adjacent to each other through another layer. In one or moreembodiments, at least one non-cellulose ester layer and at least onecellulose ester layer are in direct contact with each other when formingan interlayer or laminate. In such embodiments, the non-cellulose esterlayers and cellulose ester layers are desirably directly bonded to eachother, although adhesive agents may be utilized to enhance this bond.Generally, this bond can be a heat bond which forms when the layers arelaid up against each other and the multilayer interlayer is heated toabove the Tg of all layers. This can occur, for example, by laying upthe layers against each other and heat pressing or by co-extruding thelayers, or a combination of both.

In various embodiments, the multilayered interlayers described hereincomprise at least two polymer layers (e.g., a single layer or multiplelayers co-extruded) disposed in direct or indirect contact with eachother, desirably in direct contact with each other, wherein theinterlayers comprise at least one cellulose ester layer and at least onenon-cellulose ester layer.

When three or more layers are employed in the multilayered interlayers,some of the layers can be referred to as skin layers and one or more maybe referred to as core layers. As used herein, “skin layer” generallyrefers to outer layers of the interlayer and “one or more core layers”generally refers to one or more of the inner layer(s) disposed betweenthe skin layers. At least one side of a core layer can be in directcontact with at least one side of a skin layer or may be in indirectcontact with a skin layer through a tie layer, a coating or adhesiveagent.

Exemplary multilayer interlayer embodiments include: non-celluloseester/cellulose ester/non-cellulose ester (e.g., a skin layer/corelayer/skin layer), non-cellulose ester/cellulose ester (e.g.,skin/core), non-cellulose ester/cellulose ester/non-celluloseester/non-cellulose ester (e.g., skin/core/core/skin), or non-celluloseester/non-cellulose ester/cellulose ester/non-celluloseester/non-cellulose ester (e.g., skin/core/core/core/skin). Otherembodiments are possible, as would be known to one skilled in the art.

FIG. 1 depicts an exemplary structural laminate 10 comprising acellulose ester layer 12 and two non-cellulose ester layers 14, whichform the multilayer interlayer 16. As shown in FIG. 1, the interlayer 16is interposed between two rigid substrates 18, such as glass.

The multilayer interlayers described herein can also have more thanthree layers (e.g., at least 4, at least 5, at least 6, or up to 10 ormore individual layers), so long as at least one of the layers is anon-cellulose ester layer and one layer is a cellulose ester layer. Invarious embodiments, the multilayer interlayers can contain 2, 3, 4, ormore of the non-cellulose ester layers and 2 or more of them can be indirect contact with each other, with a cellulose ester layer, or withother types of layers. The multilayer interlayer can contain 2, 3, 4, ormore cellulose ester layers, and they can be in direct contact with eachother, with the non-cellulose ester layer(s), or with other types oflayers. Desirably, in the multilayer interlayer structures having atleast 3 layers, at least one cellulose ester layer is disposed betweentwo non-cellulose ester layers to provide the rigidity and stiffness toan interlayer. The non-cellulose ester layers can have varyingthicknesses, which are largely determined by the type of interlayer orlaminate that the layer is being used in, and can be any of thethicknesses previously discussed for the cellulose layer.

The non-cellulose ester layers described herein can further include atleast one plasticizer. Depending on the specific composition of thethermoplastic resin forming the non-cellulose layers, the plasticizermay be present in an amount of at least 1, at least 2, at least 3, atleast 4, at least 5, at least 10, at least 15, at least 20, at least 25,at least 30, at least 35, at least 40, at least 45, at least 50, atleast 55, at least 60 phr and/or not more than 120, not more than 110,not more than 105, not more than 100, not more than 95, not more than90, not more than 85, not more than 75, not more than 70, not more than65, not more than 60, not more than 55, not more than 50, not more than45, or not more than 40 phr, although other amounts may be useddepending on the materials and desired properties. In some embodiments,there may be no added plasticizer.

For layers of unknown plasticizer content, the plasticizer content canbe determined via a wet chemical method in which an appropriate solvent,or mixture of solvents, is used to extract the plasticizer from thepolymer layer or interlayer. Prior to extracting the plasticizer, theweight of the sample layer is measured and compared with the weight ofthe layer from which the plasticizer has been removed after extraction.Based on this difference, the weight of plasticizer can be determinedand the plasticizer content, in phr, calculated. For multiple layerinterlayers, the polymer layers can be physically separated from oneanother and individually analyzed according to the above procedure.

Notably, for a given type of plasticizer, the compatibility of theplasticizer in the non-cellulose ester layer is largely determined bythe hydroxyl content of the thermoplastic resin forming the layer,especially when, for example, the thermoplastic resin comprisespoly(vinyl acetal). Thermoplastic resins with greater residual hydroxylcontent are typically correlated with reduced plasticizer compatibilityor capacity, typically due to the hydrophobicity of the plasticizerbeing more compatible with fewer hydrophilic groups present on thepolymer chain. Conversely, polymers with a lower residual hydroxylcontent typically will result in increased plasticizer compatibility orcapacity. Generally, this correlation between the residual hydroxylcontent of a polymer and plasticizer compatibility/capacity can bemanipulated and exploited to allow for addition of the proper amount ofplasticizer to the polymer resin and to stably maintain differences inplasticizer content between multiple interlayers. Examples of suitableplasticizers that may be used to produce the non-cellulose ester layerscan include any of the above-described plasticizers that are used toproduce the cellulose ester layers.

In various embodiments, the cellulose ester layers and non-celluloseester layers can exhibit different glass transition temperatures. Thedifference in the glass transition temperature of the cellulose esterlayer and the glass transition temperature of the non-cellulose esterlayers can be at least 3° C., at least 5° C., at least 8° C., at least10° C., at least 12° C., at least 15° C., at least 18° C., at least 20°C., at least 22° C., or at least 25° C. or more.

The glass transition temperatures of the non-cellulose ester layersdescribed herein were determined by dynamic mechanical thermal analysis(DMTA) according to the following procedure. A polymer sheet is moldedinto a sample disc of 25 millimeters (mm) in diameter. The polymersample disc is placed between two 25-mm diameter parallel plate testfixtures of a Rheometrics Dynamic Spectrometer II. The polymer sampledisc is tested in shear mode at an oscillation frequency of 1 Hertz asthe temperature of the sample is increased from −20 to 70° C. at a rateof 2° C./minute. The position of the maximum value of tan delta(damping) plotted as dependent on temperature is used to determine theglass transition temperature. Experience indicates that the method isreproducible to within +/−1° C.

The types of thermoplastic resins that can be used to form thenon-cellulose ester layers are now described in further detail below.

EVA Layers

In various embodiments, the non-cellulose ester layer described hereincan comprise, consist essentially of, or consist of an ethylene vinylacetate (“EVA”) resin. In such embodiments, the non-cellulose esterlayer may also be referred to as an “EVA layer.” These materials arecommercially available, for example, as EVALAYER EV070C clear EVA film(from Interlayer Solutions), and as VISTASOLAR® 520.68 film (from TPIAll Seasons Co., LTD), as well as from other suppliers.

In embodiments where the non-cellulose ester layer comprises EVA, thelayer can contain minute amounts of plasticizer. For example, the EVAlayer may comprise less than 20, less than 15, less than 10, less than5, less than 2, or less than 1 phr of plasticizer when the layercomprises EVA. In certain embodiments, the EVA layer does not containany plasticizers when the layer comprises EVA.

EVA having different levels of vinyl acetate co-monomer can be used,depending on the desired properties. In certain embodiments, the EVAcomprises a vinyl acetate content of at least 70, at least 80, or atleast 90 and/or not more than 99, not more than 98, or not more than 95weight percent. In this range, the EVA may be miscible in the celluloseester. In other embodiments, the vinyl acetate content may be less than70 weight percent, such as at least about 10, or at least about 15, orat least about 20, or at least about 25 or more and/or not more thanabout 45, not more than about 40, not more than about 35 weight percent,or from about 20 to about 40 or about 25 to about 35 weight percent,although different amounts may be used depending on the desiredapplication and properties.

In various embodiments, the EVA comprises a formulated EVA, which inembodiments, contains a silane additive, a peroxide additive, aco-activator, a UV blocker, and an antioxidant. Alternatively, the EVAcan comprise an “unformulated” EVA, which is missing one of the abovelisted components contained in the formulated EVA, such as a peroxideadditive (in which case the EVA would no longer be thermally reactive).In various embodiments, the EVA can be maleated.

The EVA layers can be used in conjunction with the cellulose esterlayers described herein to produce various types of multilayerinterlayers, which can include other types of layers includingpoly(vinyl acetal) layers, such as polyvinyl butyral (“PVB”) layers.Exemplary multilayer interlayer configurations include: EVA/celluloseester/EVA (e.g., skin/core/skin); EVA/cellulose ester polymer blend/EVA(e.g., skin/core/skin); and PVB/EVA/cellulose ester/EVA/PVB (e.g.,skin/core/core/core/skin).

Although not wishing to be bound by theory, it is believed that the EVAlayers can also function as tie layers between poly(vinyl acetal) layersand the cellulose esters and can enhance the bond between these twolayers. In such embodiments, the EVA layers can be at least partiallyinterposed between the poly(vinyl acetal) and the cellulose esterlayers. In other embodiments, the EVA can be a separate layer that isnot a tie layer.

Multilayer interlayers containing an EVA layer and a cellulose esterlayer can be produced using any method known in the art. For example,each layer may be formed separately using techniques known in the artand then laminated together. Alternatively, multilayer interlayerscontaining an EVA layer and a cellulose ester layer may be produced viaco-extrusion.

Due to the crosslinking properties of EVA, it is generally desirable toavoid fully crosslinking the EVA when forming the EVA layer. Typically,partially crosslinked EVA is still able to be co-extruded with celluloseesters to form the multilayer interlayers. Thus, it can be desirable toutilize extrusion temperatures that do not fully crosslink the EVA.

Thermoplastic Polyurethane Layers

In various embodiments, the non-cellulose ester layer described hereincan comprise, consist essentially of, or consist of a thermoplasticpolyurethane (“TPU”) resin. In such embodiments, the non-cellulose esterlayer may also be referred to as a “TPU layer.” One example is ProductA4700NAT (commercially available from Deerfield Urethane). In variousembodiments, the TPU can comprise an aliphatic isocyanate-polyether orpolyester urethane. Additionally, in certain embodiments, the TPU mayalso comprise a UV stabilizer and an antioxidant in order to provideadditional stability to the TPU when it is exposed to heat and UV light.

In embodiments where the non-cellulose ester layer comprises a TPU, thelayer can contain minute amounts of plasticizer. For example, the TPUlayer may comprise less than 10, less than 5, less than 2, or less than1 phr of plasticizer. In certain embodiments, the TPU layer does notcontain any plasticizers.

The TPU layers can be used in conjunction with the cellulose esterlayers described herein to produce various types of multilayerinterlayers, which may also include poly(vinyl acetal) or PVB layers.Exemplary multilayer interlayer configurations include: TPU/celluloseester/TPU (e.g., skin/core/skin); TPU/cellulose ester polymer blend/TPU(e.g., skin/core/skin); and PVB/TPU/cellulose ester/TPU/PVB (e.g.,skin/core/core/core/skin).

Although not wishing to be bound by theory, it is believed that the TPUlayers can function as tie layers between poly(vinyl acetal) layers andthe cellulose esters and can enhance the bond between these two layers.In such embodiments, the TPU layers can be at least partially interposedbetween the poly(vinyl acetal) and the cellulose ester layers. In otherembodiments, the TPU can be a separate layer that is not a tie layer.

Multilayer interlayers containing a TPU layer and a cellulose esterlayer can be produced using any method known in the art. For example,each layer may be formed separately using techniques known in the artand then laminated together. Alternatively, multilayer interlayerscontaining a TPU layer and a cellulose ester layer may be produced viaco-extrusion.

Ionomer Layers

In various embodiments, the non-cellulose ester layer described hereincan comprise, consist essentially of, or consist of an ionomer resin. Insuch embodiments, the non-cellulose ester layer may also be referred toas an “ionomer layer.”

Generally, the ionomer resin can comprise partially neutralizedacid-ethylene copolymers. Furthermore, the ionomer resin can have anacid functionality in the range of from 0.1 to 30 weight percent, from 1to 25 weight percent, or from 5 to 20 weight percent, based on the totalweight of the polymer. In one or more embodiments, the ionomer resin canhave at least 0.1, at least 1, at least 5, at least 10, at least 15weight percent and/or not more than 30, not more than 25, or not morethan 20 weight percent acid functionality from one or more acrylicacids. Such acrylic acids can include, for example, acrylic acid, maleicacid, maleic anhydride, methacrylic acid, itaconic acid, fumaric acid,monomethyl maleic acid, and mixtures thereof.

Furthermore, in various embodiments, the ethylene copolymer can beselected from the group consisting of acrylates, methacrylates, andcombinations thereof. In such embodiments, the methacrylates cancomprise methyl acrylate, methyl methacrylate, butyl acrylate, butylmethacrylate, glycidyl methacrylate, vinyl acetate, and mixturesthereof. Ionomer resins are further described in U.S. Pat. No. 8,399,097and U.S. Pat. No. 8,399,098, the disclosures of which are incorporatedherein by reference in their entireties.

In embodiments where the non-cellulose ester layer comprises an ionomer,the layer can contain minute amounts of plasticizer. For example, theionomer layer may comprise less than 10, less than 5, less than 2, orless than 1 phr of plasticizer. In certain embodiments, the ionomerlayer does not contain any plasticizers.

The ionomer layers can be used in conjunction with the cellulose esterlayers described herein to produce various types of multilayerinterlayers, which may also include poly(vinyl acetal) layers. Exemplarymultilayer interlayer configurations include: ionomer/celluloseester/ionomer (e.g., skin/core/skin); ionomer/cellulose ester polymerblend/ionomer (e.g., skin/core/skin); and PVB/ionomer/celluloseester/ionomer/PVB (e.g., skin/core/core/core/skin).

Multilayer interlayers containing an ionomer layer and a cellulose esterlayer can be produced using any method known in the art. For example,each layer may be formed separately using techniques known in the artand then laminated together. Alternatively, multilayer interlayerscontaining an ionomer layer and a cellulose ester layer may be producedvia co-extrusion.

Poly(Vinyl Acetal) Layers

In various embodiments, the non-cellulose ester layer described hereincan comprise, consist essentially of, or consist of a poly(vinyl acetal)resin, such as polyvinyl butyral. The poly(vinyl acetal) layers can beused in conjunction with the cellulose ester layers described herein toproduce various types of multilayer interlayers. Exemplary multilayerinterlayer configurations include: PVB/adhesive coating/cellulose esterpolymer/adhesive coating/PVB (e.g., skin/core/skin) and PVB/celluloseester polymer blend/PVB (e.g., skin/core/skin).

The poly(vinyl acetal) resin can be produced formed by acetalization ofpoly(vinyl alcohol) with one or more aldehydes in the presence of acatalyst according to known methods such as, for example, thosedescribed in U.S. Pat. Nos. 2,282,057 and 2,282,026, as well as Wade, B.2016, Vinyl Acetal Polymers, Encyclopedia of Polymer Science andTechnology. 1-22 (online, copyright 2016 John Wiley & Sons, Inc.), theentire disclosures of which are incorporated herein by reference intheir entireties.

Poly(vinyl acetal) resins typically have a residual hydroxyl content, anester content, and an acetal content. As used herein, residual hydroxylcontent (calculated as PVOH) refers to the weight percent of moietieshaving a hydroxyl group remaining on the polymer chains. For example,poly(vinyl acetal) can be manufactured by hydrolyzing poly(vinylacetate) to PVOH, and then reacting the PVOH with an aldehyde, such asbutyraldehyde, propionaldehyde, and the like, and desirablybutyraldehyde, to make a polymer having repeating vinyl butyral units.In the process of hydrolyzing the poly(vinyl acetate), typically not allof the acetate side groups are converted to hydroxyl groups. Forexample, reaction with butyraldehyde typically will not result in theconversion of all hydroxyl groups on the PVOH to acetal groups.Consequently, in any finished polyvinyl butyral, there typically will beresidual ester groups such as acetate groups (as vinyl acetate groups)and residual hydroxyl groups (as vinyl hydroxyl groups) as side groupson the polymer chain and acetal (e.g., butyral) groups (as vinyl acetalgroups). As used herein, residual hydroxyl content is measured on aweight percent basis per ASTM 1396.

In various embodiments, the poly(vinyl acetal) resin comprises apolyvinyl butyral resin, which is also interchangeably referenced hereinas “PVB.” An example of a polyvinyl butyral structure is used to furtherillustrate how the weight percentages are based from the moiety unit towhich is bonded the relevant pendant group:

Taking the above structure of polyvinyl butyral, the butyral or acetalcontent is based on the weight percentage of unit A in the polymer, theOH content is based on the weight percentage of unit B in the polymer (apolyvinyl OH moiety or PVOH), and the acetate or ester content is basedon the weight percentage of unit C in the polymer.

The hydroxyl group content of the poly(vinyl acetal) resin is notparticularly limited, but suitable amounts are from at least 6, at least8, at least 10, at least 11, at least 12, at least 13, at least 14, atleast 15, at least 16, or at least 17 and in each case up to 35 weightpercent or more of PVOH. In general, a poly(vinyl acetal) resin having alower hydroxyl weight percentage has the capability of absorbing moreplasticizer and absorbing it more efficiently.

Where optical clarity is desired, however, the hydroxyl weightpercentage can have an influence on the refractive index of thepoly(vinyl acetal) resin. Therefore, depending on the type of celluloseester selected, the hydroxyl weight percentage of the poly(vinyl acetal)can be adjusted along with the amount of plasticizer to achieve thedesired refractive index where optical clarity is desirable.

The poly(vinyl acetal) resin can also comprise 20 weight percent orless, 17 weight percent or less, 15 weight percent or less, 13 weightpercent or less, 11 weight percent or less, 9 weight percent or less, 7weight percent or less, 5 weight percent or less, or 4 weight percent orless of residual ester groups calculated as polyvinyl ester, e.g.,acetate, with the balance being an acetal, e.g., butyraldehyde acetal,but optionally including other acetal groups in a minor amount, forexample, a 2-ethyl hexanal group (see U.S. Pat. No. 5,137,954, theentire disclosure of which is incorporated herein by reference). As withthe residual hydroxyl group measurement, the weight percent of residualester groups (e.g., residual acetate content) is based on the moiety inthe polymer backbone onto which is linked the acetate group, includingthe pendant acetate group.

The poly(vinyl acetal) resin used in the invention can also have anacetal content of at least 50, at least 55, at least 60, at least 65, atleast 70, at least 75, at least 80, at least 85, or at least 90 weightpercent. Additionally or alternatively, the acetal content can be up to94, up to 93, up to 92, up to 91, up to 90, up to 89, up to 88, up to86, up to 85, up to 84, up to 83, up to 82, up to 80, up to 78, up to77, up to 75, up to 70, or up to 65 weight percent.

The acetal groups in the poly(vinyl acetal) resins can comprise vinylpropynal groups or vinyl butyral groups. In one or more embodiments, theacetal groups comprise vinyl butyral groups. In some embodiments, thepoly(vinyl acetal) resin can include residues of any aldehyde and, insome embodiments, may include residues of at least one C₄ to C₈aldehyde. Examples of suitable C₄ to C₈ aldehydes can include, forexample, n-butyraldehyde, i-butyraldehyde, 2-methylvaleraldehyde,n-hexyl aldehyde, 2-ethylhexyl aldehyde, n-octyl aldehyde, andcombinations thereof. One or more of the poly(vinyl acetal) resinsutilized in the layers and interlayers described herein can include atleast 20, at least 30, at least 40, at least 50, at least 60, or atleast 70 weight percent of residues of at least one C₄ to C₈ aldehyde,based on the total weight of aldehyde residues of the resin.Alternatively, or in addition, the poly(vinyl acetal) resin may includenot more than 99, not more than 90, not more than 85, not more than 80,not more than 75, not more than 70, or not more than 65 weight percentof at least one C₄ to C₈ aldehyde. The C₄ to C₈ aldehyde may be selectedfrom the group listed above, or it can be selected from the groupconsisting of n-butyraldehyde, i-butyraldehyde, 2-ethylhexyl aldehyde,and combinations thereof.

The weight average molecular weight of the poly(vinyl acetal) resin isnot particularly limited. The poly(vinyl acetal) resin can have a weightaverage molecular weight (Mw) of at least 20,000, at least 30,000, atleast 40,000, at least 50,000, at least 60,000, or at least 70,000, withno particular upper limit, although practically up to 300,000 Daltons issuitable, although higher molecular weights maybe be used in some cases,and in each case as measured by size exclusion chromatography using thelow angle laser light scattering (SEC/LALLS) method of Cotts and Ouanoin tetra-hydrofuran as described below.

Multilayer interlayers containing a poly(vinyl acetal) layer and acellulose ester layer can be produced using any method known in the art.For example, each layer may be formed separately using techniques knownin the art and then laminated together. Alternatively, multilayerinterlayers containing a poly(vinyl acetal) layer and a cellulose esterlayer may be produced via co-extrusion.

The poly(vinyl acetal) layers can comprise a plasticizer in the amountsdisclosed above in regard to the non-cellulose ester. Furthermore, theplasticizers used in the poly(vinyl acetal) layers can include any ofthose discussed above in reference to the cellulose ester layer and thenon-cellulose ester layer.

Although not wishing to be bound by theory, it is assumed that thecompatibility of a given plasticizer with a poly(vinyl acetal) resin candepend, at least in part, on the composition of the polymer, and, inparticular, on its residual hydroxyl content. Overall, poly(vinylacetal) resins with higher residual hydroxyl contents tend to exhibit alower compatibility (or capacity) for a given plasticizer as compared tosimilar resins having a lower residual hydroxyl content. As a result,poly(vinyl acetal) resins with higher residual hydroxyl contents tend tobe less plasticized and exhibit higher stiffness than similar resinshaving lower residual hydroxyl contents. Conversely, poly(vinyl acetal)resins having lower residual hydroxyl contents may tend to, whenplasticized with a given plasticizer, incorporate higher amounts ofplasticizer, which may result in a softer resin layer that exhibits alower glass transition temperature than a similar resin having a higherresidual hydroxyl content. Depending on the specific resin andplasticizer, these trends could be reversed.

In various embodiments, a non-cellulose ester layer comprising at leastone poly(vinyl acetal) resin can contribute to a higher glass/interlayeradhesion and/or a better ability to absorb impact energy. In one or moreembodiments, the Tg of the non-cellulose ester layer comprising at leastone poly(vinyl acetal) resin is not greater than 50° C., not greaterthan 49° C., not greater than 48° C., not greater than 47° C., notgreater than 46° C., not greater than 45° C., not greater than 44° C.,not greater than 43° C., not greater than 42° C., not greater than 41°C., not greater than 40° C., not greater than 39° C., not greater than38° C., not greater than 37° C., not greater than 36° C., not greaterthan 37° C., not greater than 36° C., not greater than 35° C., notgreater than 34° C., not greater than 33° C., not greater than 32° C.,not greater than 31° C., or not greater than 30° C. and in each case atleast −20° C., at least 0° C., or at least 25° C.

Additionally or alternatively, the Tg of a non-cellulose ester layercomprising a poly(vinyl acetal) resin can be at least 10° C., at least20° C., at least 30° C., at least 40° C., at least 45° C., at least 50°C., at least 60° C., at least 65° C., at least 70° C., at least 75° C.,at least 80° C., at least 85° C., at least 90° C., at least 95° C., atleast 100° C., at least 110° C., at least 120° C., or at least 130° C.less than the Tg of at least one of the cellulose ester layers. Theglass transition temperature is measured using DMTA as described above.

In various embodiments, the poly(vinyl acetal) layers can be used inconjunction with the cellulose ester layers to produce acousticinterlayers. Often, polymers that exhibit one set of desirableproperties, such as acoustic performance, lack other desirableproperties, such as impact resistance or strength. Therefore, in orderto achieve desirable combinations of properties, multilayeredinterlayers can be produced containing a poly(vinyl acetal) layerexhibiting desirable acoustic performance and a cellulose ester layerproviding impact strength and resistance. These multilayered interlayersmay include at least one inner cellulose ester layer sandwiched betweentwo outer poly(vinyl acetal) layers. Alternatively, these multilayeredinterlayers may contain one or more poly(vinyl acetal) layers exhibitingdesirable acoustical properties placed on at least one cellulose esterlayer. In such embodiments, the poly(vinyl acetal) layers will generallybe softer and exhibit a lower glass transition temperature compared tothe cellulose ester layer, which enhances its acoustic performance. Inone or more embodiments, the acoustic interlayers can contain apoly(vinyl acetal) layer having a Tg of at least −30, at least −25, atleast −20, at least −15, at least −10, at least −5, or at least 0° C.and/or less than 40, less than 30, less than 25, less than 20, less than15, less than 10, or less than 5° C.

Furthermore, in various embodiments, this poly(vinyl acetal) resin orpoly(vinyl acetal) layer may exhibit enhanced acoustic properties, suchas, for example, an improved tan delta as compared to a comparablepoly(vinyl n-butyral) resin layer. Tan delta is the ratio of the lossmodulus (G″) in Pascals to the storage modulus (G′) in Pascals of aspecimen measured by Dynamic Mechanical Thermal Analysis (DMTA). TheDMTA is performed with an oscillation frequency of 1 Hz under shear modeand a temperature sweep rate of 3° C./min. The peak value of the G″/G′curve at the glass transition temperature is the tan delta value. Highertan delta values are indicative of higher damping, which can translateto better sound dampening, or acoustic, performance.

Moreover, in various embodiments, the poly(vinyl acetal) resin orpoly(vinyl acetal) layer may exhibit a damping loss factor, or lossfactor, of at least 0.10, at least 0.15, at least 0.17, at least 0.20,at least 0.25, at least 0.27, at least 0.30, at least 0.33, or at least0.35. Loss factor is measured by Mechanical Impedance Measurement asdescribed in ISO Standard 16940. To measure the loss factor, polymersamples are laminated between two sheets of clear glass, each having athickness of 2.3 mm, and are prepared to have a width of 25 mm and alength of 300 mm. The laminated samples are then excited at the centerpoint using a vibration shaker, commercially available from Brüel andKjær (Nærum, Netherlands) and an impedance head is used to measure theforce required to excite the bar to vibrate and the velocity of thevibration. The resultant transfer function is recorded on a NationalInstrument data acquisition and analysis system and the loss factor atthe first vibration mode is calculated using the half power method.

According to some embodiments, the poly(vinyl acetal) resin orpoly(vinyl acetal) layer may exhibit desirable acoustic properties, asindicated by, for example, the reduction in the transmission of sound asit passes through (i.e., the sound transmission loss of) the interlayer.In some embodiments, acoustic interlayers may exhibit a soundtransmission loss at the coincident frequency, measured according toASTM E90 at 20° C., of at least 34, at least 34.5, at least 35, at least35.5, at least 36, at least 36.5, or at least 37 dB. During such soundtransmission tests, the interlayers are laminated between two sheets of2.3 mm clear glass and the test is conducted at a reference frequency of3,150 Hz.

Tie Layers

In various embodiments, one or more of the non-cellulose ester layersdescribed herein can be a tie layer. As used herein, a “tie layer”refers to a layer or sheet in an interlayer that bonds at least twoother layers together. The tie layer can comprise, consist essentiallyof, or consist of a thermoplastic resin selected from the groupconsisting of cellulose, EVA, TPU, ionomer, polyvinyl acetate, ethylenevinyl alcohol, and combinations thereof. If cellulose is used as a tielayer, it cannot be co-extruded, but can be incorporated in variousother methods known in the art.

In embodiments where the non-cellulose ester layer comprises a tielayer, the layer can contain minute amounts of plasticizer. For example,the tie layer may comprise less than 10, less than 5, less than 2, orless than 1 phr of plasticizer. In certain embodiments, the tie layerdoes not contain any plasticizers.

The tie layers can be used in conjunction with the cellulose esterlayers described herein to enhance the bonds between the cellulose esterlayers and various other layers in the multilayer interlayers,especially poly(vinyl acetal) or PVB layers. Exemplary multilayerinterlayer configurations containing the tie layers include PVB/tielayer/cellulose ester/tie layer/PVB (e.g., skin/core/core/core/skin). Insuch embodiments, the tie layers can be at least partially interposedand/or positioned between the poly(vinyl acetal) layers and thecellulose ester layers.

In various embodiments, the interlayer exhibits a compressive shearadhesion (“CSA”) between the cellulose ester layer and the tie layer ofat least 5, at least 6, at least 7, at least 8, at least 9, at least 10,at least 11, at least 12, at least 13, at least 14, or at least 15and/or not more than 50, not more than 45, not more than 40, not morethan 35, not more than 30, or not more than 25 MPa. Compressive shearadhesion measurements are made with an Alpha Technologies T-20Tensometer equipped with a special 45° compressive shear sample holderor jig. The laminate is drilled into at least five 1.25 inch diameterdiscs and kept at room temperature for 24 hours before performing theCSA test. The disc is placed on lower half of the jig and the other halfof the jig is placed on top of the disc. The cross-head travels at 3.2mm/min downward causing a piece of the disc to slide relative to theother piece. The compressive shear strength of the disc is the shearstress required to cause the adhesion to fail.

Multilayer interlayers containing a tie layer and a cellulose esterlayer can be produced using any method known in the art. For example,each layer may be formed separately using techniques known in the artand then laminated together. Alternatively, multilayer interlayerscontaining a tie layer and a cellulose ester layer may be produced viaco-extrusion.

Adhesive Coatings

According to various embodiments of the present invention, theinterlayers may include at least one adhesive coating comprising,consisting essentially of, or consisting of at least one adhesive agent.The adhesive agent can be any compound or material that facilitatesadhesion between the surface of the cellulose ester layer and anotherlayer in the multilayer interlayers. Rather than be incorporated intothe cellulose ester layer, the adhesive agent according to embodimentsof the present invention may be present on at least a portion of thesurface of the cellulose ester layer prior to adhering the layer toanother layer when forming the laminate or interlayer. FIG. 2 depicts anexemplary structural laminate 10 comprising a cellulose ester layer 12,two non-cellulose ester layers 14, and two adhesive coatings 20, whichform the multilayer interlayer 16. As shown in FIG. 2, the interlayer 16is interposed between two rigid substrates 18, such as glass.

In various embodiments, the adhesive agent can be selected from thegroup consisting of maleic anhydride, a silanol compound or a precursorthereof, a boron atom containing compound, such as a borate compound, ahydroxyl containing polymer such as ethylene vinyl alcohol (EVOH),polyamides, and the like, a low molecular weight cellulose ester, andcombinations thereof. In one or more embodiments, the adhesive coatingcomprises at least 1, at least 2, at least 3, at least 4, at least 5, atleast 10, at least 15, at least 20, at least 25, at least 30, at least35, at least 40, at least 45, at least 50, at least 55, at least 60, atleast 65, at least 70, at least 75, at least 80, at least 85, at least90, at least 95, or at least 99 weight percent of the adhesive agent.

In various embodiments, the adhesive agent can comprise asilicone-containing compound such as a silane or silanol. Examples ofsuitable silicon-containing compounds can include organic alkoxysilanesincluding monoalkoxysilanes, dialkoxysilanes, and trialkoxysilanes. Insome embodiments, the silicon-containing compound may be atrialkoxysilane such as, for example, a trimethoxysilane or atriethoxysilane. Examples of suitable trialkoxysilanes can include, butare not limited to, γ-glycidoxypropyltrimethoxysilane,aminopropyltriethyoxysilane, aminoethylaminopropyl-trimethoxysilane, andcombinations thereof. When the silicon-containing compound comprises asilanol, it may comprise the hydrolyzed form of one or more of thesilicon-containing compound listed above. In certain embodiments, thesilicone-containing adhesive agent or precursor thereto comprises analkoxysilane.

In various embodiments, the adhesive agent can comprise a maleicanhydride copolymer. In one or more embodiments, the maleic anhydride isselected from the group consisting of styrene maleic anhydridecopolymers, maleic anhydride grafted polypropylene, copolymers of maleicanhydride with olefins and/or acrylic esters, and combinations thereof.

In some embodiments, the adhesive agent can be added to the surface ofthe cellulose ester layer by applying a coating material to at least aportion of the sheet surface. The coating material can include theadhesive agent, or a precursor thereto, and at least one carrier liquid.When an adhesive agent precursor is present in the coating material, atleast a portion of the precursor can be converted to an adhesive agentupon application to the sheet. Alternatively, at least a portion of theprecursor may be converted to the adhesive agent within the coatingmaterial, or the coating material may include the adhesive agent itself.

The coating material may further include at least one carrier liquidcapable of dissolving or dispersing the adhesive agent, or precursorthereto, and for facilitating application of the adhesive agent orprecursor to the surface of the polymer sheet. In some embodiments, thecarrier liquid can comprise an aqueous carrier that can include, or be,water, while, in some embodiments, the carrier liquid can be an organiccarrier that comprises one or more organic solvents, such as, forexample, methanol. In some embodiments, the carrier liquid can comprisea mixture of water and one or more organic solvents, such as, forexample, methanol. Depending on the type and amount of the adhesiveagent present, the coating material can have a pH of at least 1, atleast 1.5, at least 2, at least 2.5, at least 3, at least 3.5, at least4, at least 4.5 and/or not more than 7, not more than 6.5, not more than6, not more than 5.5, or not more than 5, or a pH in the range of from 1to 7, 1.5 to 5.5, or 2 to 5. In some embodiments, the coating materialcan have a pH of at least 8, at least 8.5, at least 9, at least 9.5and/or not more than 14, not more than 13, not more than 12, not morethan 11, or in the range of from 8 to 14, 8.5 to 13, 9 to 12, or 9.5toll.

The adhesive agent, or its precursor, may be present in the coatingmaterial in any concentration and, in some embodiments, may be presentin an amount of at least 0.004, at least 0.005, at least 0.0075, atleast 0.010, at least 0.025, at least 0.050, at least 0.10, at least0.25, at least 0.75, at least 1, at least 1.25, at least 1.5, at least2, at least 2.5, at least 5 and/or not more than 25, not more than 20,not more than 15, not more than 12, not more than 10, not more than 7.5,not more than 5, not more than 2.5, not more than 2, or not more than1.5 weight percent, based on the total weight of the coating material,or an amount in the range of from 0.004 to 25, 0.0075 to 20, 0.010 to15, or 0.25 to 7.5 weight percent, based on the total weight of thecoating material.

The coating material can be applied to at least one surface of thecellulose ester sheet according to any suitable method. In someembodiments, at least a portion of the sheet may be dip coated, suchthat all or a portion of the sheet is submerged in the coating material.In other embodiments, the coating material may be applied to at least aportion of the cellulose ester layer surface by spray coating. Othersuitable coating methods, including, for example, gravure coating orinkjet printing, may also be used. When the sheet is dip coated, the diptime can be at least 0.5 seconds, at least 30 seconds, at least 1, atleast 2, at least 5, at least 10, at least 30, at least 60 minutesand/or not more than 90, not more than 60, not more than 30, not morethan 15 minutes, or not more than 10 minutes, or in the range of from0.5 seconds to 90 minutes, 30 seconds to 30 minutes, or 1 minute to 10minutes.

In some embodiments, the amount of adhesive agent present at the surfaceof the cellulose ester layer can be characterized using X-rayphotoelectron spectroscopy (XPS). The XPS method used to obtain numericvalues for the amount of adhesive agent described herein is performedusing an AXIS Nova spectrometer (commercially available from KratosAnalytics Ltd, Manchester, UK) with CasaXPS software version 2.3.17. Thequantification is based on a wide scan survey spectra and was reportedin relative atomic mole percent. Unless otherwise specified, all surveyspectra obtained during the analysis are collected with an Al Kαmonochromatic source operating at 150 W (15 kV, 10 mA) with a passenergy of 80 eV. The acceptance angle was +/−15° in spectroscopy mode,with a take-off angle of 90° and an analysis area of 700×300 μm. Thecharge neutralization was on and the charge correction was C 1s 284.8eV. The narrow scan (high resolution) spectra were collected forelements of interest, including carbon, oxygen, and silicon, for peakfitting to elucidate oxidation states/chemical environments. Thesenarrow spectra were collected using the same parameters described abovefor the wide scan with the exception of pass energy. Unless otherwisespecified, the narrow scan spectra were collected using 20 eV passenergy.

According to some embodiments, the amount of silicon, or other adhesiveagent or marker thereof, present at the surface of the cellulose esterlayer may be at least 0.10, at least 0.30, at least 0.50, at least 0.75and/or not more than 15, not more than 10, not more than 5, not morethan 3, not more than 1.5, not more than 1.25 atomic percent, measuredby the XPS method described above. The amount of silicon, or otheradhesive agent or marker thereof, present at the surface of thecellulose ester layer can be in the range of from 0.10 to 15, 0.3 to 3,0.50 to 1.5 atomic percent (at %), measured as described above.

The surface-treated locations of the cellulose ester layer can bepresent on substantially all, or a portion, of the surface of thecellulose ester layer. In some embodiments, only a portion of thesurface of the cellulose ester layer can be treated, such that, forexample, at least 5, at least 10, at least 15, at least 20, at least 30,or at least 40 percent of the surface of the layer remains untreated,while, in other embodiments, nearly all of the surface of the layer maybe treated. In some embodiments, at least 5, at least 10, at least 15,at least 20, at least 30, at least 40, at least 50, at least 60, atleast 70, at least 80, or at least 90 percent of the total surface areaof the cellulose ester layer may be treated with the adhesive agent asdescribed above.

As a result of the adhesive agent, the sheets and layers describedherein may be capable of maintaining adhesion to other layers orsubstrates despite high levels of moisture ingress, even when thelaminate is exposed to conditions of elevated temperature and humidity.For example, the layers and interlayers according to embodiments of thepresent invention may exhibit such a peel adhesion while having anaverage moisture content of at least 0.4, at least 0.5, at least 0.7, orat least 1 percent, measured by Karl-Fisher Titration according to ASTME203.

In various embodiments, the interlayer exhibits a compressive shearadhesion between the cellulose ester layer and the adhesive coating ofat least 5, at least 6, at least 7, at least 8, at least 9, at least 10,at least 11, at least 12, at least 13, at least 14, or at least 15and/or not more than 50, not more than 45, not more than 40, not morethan 35, not more than 30, or not more than 25 MPa, measured aspreviously described.

The adhesive coatings can be used in conjunction with the celluloseester layers described herein to enhance the bonds between the celluloseester layers and various other layers in the multilayer interlayers,especially poly(vinyl acetal) layers. In such embodiments, the adhesivecoatings can be at least partially interposed and/or positioned betweenthe poly(vinyl acetal) layers and the cellulose ester layers.

According to some embodiments of the present invention, the adhesivecoating that includes at least one adhesive agent, or precursor thereto,can be applied to one or more surfaces of the cellulose ester layer orinterlayer at one or more points during its production. Or, the coatingmaterial can be applied after production, as a post-production treatmentstep. In some embodiments, a method for making a polymer sheet isprovided in which at least a portion of the sheet can be coated duringits production. For example, after the sheet is extruded, or otherwiseformed according to one or more methods listed above, the coatingmaterial may be applied to at least one surface via dip coating, spraycoating, gravure coating, inkjet printing, or other coating methods. Insome embodiments, at least a portion of the sheet may be passed througha bath of coating material while still on the production line. Oncecoated, the resin can be further cooled, cut, and removed from the line.

In some embodiments, a method for treating a cellulose ester layer isprovided that comprises applying a coating material to a pre-formedcellulose ester sheet that has already been extruded, cooled, andoptionally cut to form non-continuous polymer sheets. Such pre-formedsheets may be, in some embodiments, obtained from a third partymanufacturer or another source and may be coated with at least onecoating agent according to various embodiments described above. Thepre-formed sheets may be coated and then stored, or may be coated andthen laminated to at least one rigid substrate to form a multiple layerpanel. The type and amount of the coating agent used may depend, atleast in part, on the size of the sheet and its intended use.

Methods for Producing the Interlayers and Laminates

The interlayers according to various embodiments of the presentinvention can be made by any suitable process known to one of ordinaryskill in the art of producing interlayers, and is not limited to amethod for its manufacture. For example, it is contemplated that thelayers or interlayers may be formed by extrusion or co-extrusion. In anextrusion process, one or more thermoplastic resins, plasticizers, and,optionally, one or more additives as described previously, can bepre-mixed and fed into an extrusion device. The extrusion device isconfigured to impart a particular profile shape to the thermoplasticcomposition in order to create an extruded sheet. The extruded sheet,which is at an elevated temperature and highly viscous throughout, canthen be cooled to form a polymeric sheet. Once the sheet has been cooledand set, it may be cut and rolled for subsequent storage,transportation, and/or use as an interlayer.

Co-extrusion is a process by which multiple layers of polymer materialare extruded simultaneously. Generally, this type of extrusion utilizestwo or more extruders to melt and deliver a steady volume throughput ofdifferent thermoplastic melts of different viscosities or otherproperties through a co-extrusion die into the desired final form. Thethickness of the multiple polymer layers leaving the extrusion die inthe co-extrusion process can generally be controlled by adjustment ofthe relative speeds of the melt through the extrusion die and by thesizes of the individual extruders processing each molten thermoplasticresin material.

The extrusion process can occur at temperatures of at least 120, atleast 130, at least 135, at least 140, at least 145, at least 150, atleast 155, at least 160, at least 165, at least 170, at least 175, atleast 180, at least 185, at least 190, at least 195, or at least 200° C.and/or not more than 280, not more than 270, not more than 260, not morethan 250, or not more than 240° C., although other temperatures may beapplicable depending on the materials and application.

The layers and interlayers described herein may be produced according toany suitable method. The resulting resin composition may be formed intoa sheet or layer according to any suitable method including, but notlimited to, solution casting, compression molding, injection molding,melt extrusion, melt blowing, and combinations thereof. When theinterlayers are multilayer interlayers including two or more layers orsheets, such multilayer interlayers can also be produced according toany suitable method, including, for example, co-extrusion, blown film,melt blowing, dip coating, solution coating, blade, paddle, air-knife,printing, powder coating, spray coating, and combinations thereof.

Alternatively, each layer of the interlayer can be separately formed orextruded into sheets, and the sheet can be laid up to form a laminatestructure of the desired order, and then pressed under heat and pressureto form the multilayer interlayer. In various embodiments of the presentinvention, the layers or interlayers may be formed by extrusion orco-extrusion. In an extrusion process, one or more thermoplasticpolymers, plasticizers, and, optionally, at least one additive, can bepre-mixed and fed into an extrusion device, wherein the layer orinterlayer can be melted and extruded from a die to thereby provide anextruded sheet.

Anti-blocking agents may also be added to the composition of the presentinvention to reduce the level of blocking of the interlayer. Desirably,they are added to the skin layers in the interlayer. Anti-blockingagents are known in the art, and any anti-blocking agent that does notadversely affect the properties of the interlayer may be used. Aparticularly preferred anti-blocking agent that can be successfully usedas in the multilayer interlayer while not affecting optical propertiesof the interlayer or the adhesive properties of the interlayer to glassis a fatty acid amide (see U.S. Pat. No. 6,825,255, the entiredisclosure of which is incorporated herein).

Other additives may be incorporated into any one of the above-describedlayers used to form the laminates or interlayers in order to enhance theperformance of the final product and impart certain additionalproperties to the interlayer. Such additives include, but are notlimited to, ACAs, dyes, pigments, stabilizers (e.g., ultravioletstabilizers), antioxidants, flame retardants, IR absorbers or blockers(e.g., indium tin oxide, antimony tin oxide, lanthanum hexaboride (LaB₆)and cesium tungsten oxide), processing aides, flow enhancing additives,lubricants, impact modifiers, nucleating agents, thermal stabilizers, UVabsorbers, dispersants, surfactants, chelating agents, coupling agents,adhesives, primers, reinforcement additives, and fillers, among otheradditives known to those of ordinary skill in the art.

The additives, in liquid, powder, or pellet form, are often used and canbe mixed into the thermoplastic resin or plasticizer prior to arrivingin the extruder device or combined with the thermoplastic resin insidethe extruder device. These additives are incorporated into the celluloseester or non-cellulose ester (thermoplastic) composition, and byextension the resultant multilayer interlayer, to enhance certainproperties of the interlayer and its performance in a multiple layerglass panel product.

Interlayer Properties and End Uses

The cellulose ester interlayers can be used in many applications, suchas in laminates or panels comprising one or more rigid substrates. Apanel made with the cellulose ester interlayers described herein, suchas a glass panel which comprises an interlayer laminated between twoglass substrates, can have good optical clarity. The clarity of theinterlayer laminated between glass substrates can be determined bymeasuring the haze value, which is a quantification of light nottransmitted through the sheet glass panel containing the multilayerinterlayer. The percent haze can be measured according to the followingtechnique. An apparatus for measuring the amount of haze, a Hazemeter,Model D25, which is available from Hunter Associates (Reston, Va.), canbe used in accordance with ASTM D1003-61 (Re-approved 1977)—Procedure A,using Illuminant C, at an observer angle of 2 degrees. In variousembodiments, the interlayers described herein can exhibit a haze of lessthan 10, less than 9, less than 8, less than 7, less than 6, less than5, less than 4, less than 3, less than 2, less than 1.5, less than 1,less than 0.75, or less than 0.5 percent as measured according to ASTMD1003-61.

Another parameter used to determine the optical performance istransparency, or percent visual transmittance (% T_(vis)), which ismeasured using a hazemeter, such as a Model D25 Hazemeter commerciallyavailable from Hunter Associates (Reston, Va.), in an Illuminant D65 atan observer angle of 10°. The values provided herein were obtained byanalyzing a polymer sample which had been laminated between two sheetsof clear glass, each having a thickness of 2.3 mm (commerciallyavailable from Pittsburgh Glass Works of Pennsylvania). In someembodiments, the resin compositions, layers, and interlayers of thepresent invention can have a percent visual transmittance of at least50, at least 70, at least 80, at least 81, at least 82, at least 83, atleast 84, at least 85, at least 85.5, at least 86, at least 86.5, atleast 87, at least 87.5, at least 88, or at least 90 percent or more.

Yellowness Index (“YI”) is another measure of optical quality.Yellowness Index of a polymer sheet is measured by laminating (andautoclaving) a 30 gauge (30 mil or 0.76 mm) sheet sample between twopieces of 2.3 mm clear glass using the HunterLab UltraScan XE accordingto ASTM Method E313 (formerly D-1925) (illuminant C, 2° observer angle)from spectrophotometric light transmittance in the visible spectrum. Invarious embodiments, the interlayers can exhibit a yellowness index ofless than 1.5, less than 1.0, less than 0.75, less than 0.5, less than0.4, or less than 0.3 according to ASTM E313.

The rigidity of the interlayers may also be characterized according toits three-point bending stiffness. The three-point bending stiffness, asdescribed herein, is measured for an interlayer having a known thickness(such as 30 mils) when the interlayer is laminated between two sheets of2.3 mm thick clear glass, according to ASTM D790 at room temperature. Insome embodiments, a 30 mil interlayer can have a three-point bendingstiffness of at least 150, at least 155, at least 160, at least 170, atleast 180, at least 190, at least 200, at least 210, at least 220, atleast 230, at least 240, at least 250, at least 260, at least 270, atleast 280, at least 290, or at least 300 N/mm and/or not more than 350,not more than 340, not more than 330, not more than 320, or not morethan 310 N/mm.

In addition to enhanced rigidity, interlayers according to embodimentsof the present invention can exhibit desirable impact resistance, ascharacterized by the mean break height of the interlayer, when having athickness of between 30 mils and 60 mils and when laminated between twosheets of 2.3 mm thick clear glass, measured according to ANSI/SAEZ26.1-1996 at a temperature of 70° C. In some embodiments, theinterlayers as described herein can have a mean break height, measuredas described above, of at least 10, at least 15, at least 20, at least25, at least 30, at least 35, or at least 40 feet or more. Inembodiments, the higher the mean break height, the better.

The values for mean break height provided herein are obtained using aninterlayer having a thickness of 30 mils or 60 mils laminated betweentwo 2.3-mm thick sheets of glass. The specification of values for theseparameters is not intended to, in any way, limit the thickness of theinterlayers described herein or the configuration of multiple layerpanels according to embodiments of the present invention. Rather,specification of values for these parameters is intended to provide adefinite test for determining the impact resistance, measured as meanbreak height, exhibited by an interlayer.

In some embodiments, the layers or interlayers can comprise flat layershaving substantially the same thickness along the length of the sheet.In other embodiments, one or more layers of the interlayers can bewedge-shaped or can have a wedge-shaped profile, such that the thicknessof the interlayer changes along the length of the sheet and one edge ofthe layer or interlayer has a thickness greater than the other. When theinterlayer is a multilayer interlayer, at least one, at least two, or atleast three of the layers of the interlayer can be wedge-shaped.

Turning to FIGS. 3 through 9, several embodiments of tapered interlayersare provided. FIG. 3 is a cross-sectional view of an exemplary taperedinterlayer that includes a tapered zone of varying thickness. As shownin FIG. 3, the tapered zone has a minimum thickness (T_(min)) measuredat a first boundary of the tapered zone and a maximum thickness(T_(max)) measured at a second boundary of the tapered zone. In certainembodiments, T_(min) can be at least 0.25, at least 0.40, or at least0.60 millimeters (mm) and/or not more than 1.2, not more than 1.1, ornot more than 1.0 mm. In certain embodiments, the difference betweenT_(max) and T_(min) can be at least 0.13, at least 0.15, at least 0.20,at least 0.25, at least 0.30, at least 0.35, at least 0.40 mm and/or notmore than 1.2, not more than 0.90, not more than 0.85, not more than0.80, not more than 0.75, not more than 0.70, not more than 0.65, or notmore than 0.60 mm. In certain embodiments, the distance between thefirst and second boundaries of the tapered zone (i.e. the “tapered zonewidth”) can be at least 5, at least 10, at least 15, at least 20, or atleast 30 centimeters (cm) and/or not more than 200, not more than 150,not more than 125, not more than 100 or not more than 75 cm. Further,the tapered zone width can be in the range of 5 to 200 cm, 15 to 125 cm,or 30 to 75 cm.

As shown in FIG. 3, the tapered interlayer includes opposite first andsecond outer terminal edges. In certain embodiments, the distancebetween the first and second outer terminal edges (i.e., the “interlayerwidth”) can be at least 20, at least 40, or at least 60 cm and/or notmore than 400, not more than 200, or not more than 100 cm. In theembodiment depicted in FIG. 3, the first and second boundaries of thetapered zone are spaced inwardly from the first and second outerterminal edges of the interlayer. In such embodiments, only a portion ofthe interlayer is tapered. In an alternative embodiment, discussedbelow, the entire interlayer is tapered. When the entire interlayer istapered, the tapered zone width is equal to the interlayer width and thefirst and second boundaries of the tapered zone are located at the firstand second terminal edges, respectively.

As illustrated in FIG. 3, the tapered zone of the interlayer has a wedgeangle (θ), which is defined as the angle formed between a firstreference line extending through two points of the interlayer where thefirst and second tapered zone boundaries intersect a first (upper)surface of the interlayer and a second reference line extending throughtwo points where the first and second tapered zone boundaries intersecta second (lower) surface of the interlayer. In certain embodiments, thewedge angle of the tapered zone can be at least 0.10, at least 0.13, atleast 0.15, at least 0.20, at least 0.25, at least 0.30, at least 0.35,or at least 0.40 milliradians (mrad) and/or not more than 1.2, not morethan 1.0, not more than 0.90, not more than 0.85, not more than 0.80,not more than 0.75, not more than 0.70, not more than 0.65, or not morethan 0.60 mrad.

When the first and second surfaces of the tapered zone are each planar,the wedge angle of the tapered zone is simply the angle between thefirst (upper) and second (lower) surfaces. However, as discussed infurther detail below, in certain embodiments, the tapered zone caninclude at least one variable angle zone having a curved thicknessprofile and a continuously varying wedge angle. Further, in certainembodiments, the tapered zone can include two or more constant anglezones, where the constant angle zones each have a linear thicknessprofile, but at least two of the constant angle zones have differentwedge angles. FIGS. 4 to 9 illustrate various tapered interlayersconfigured according to embodiments of the present invention.

As discussed above, the tapered interlayer can include one or moreconstant angle tapered zones, each having a width that is less than theoverall width of the entire tapered zone. Each tapered zone can have awedge angle that is the same as or different from the overall wedgeangle of the entire tapered zone. For example, the tapered zone caninclude one, two, three, four, five or more constant angle taperedzones. When multiple constant angle tapered zones are employed, theconstant angle tapered zones can be separated from one another byvariable angle tapered zones that serve to transition between adjacentconstant angle tapered zones.

The resin compositions, layers, and interlayers according to embodimentsof the present invention may be utilized in a multiple layer panel orlaminate that comprises at least one rigid substrate. Any suitable rigidsubstrate may be used and in some embodiments may be selected from thegroup consisting of glass, polycarbonate, biaxially oriented PET,copolyesters, acrylic, and combinations thereof. When the rigidsubstrate includes a polymeric material, the polymeric material may ormay not include a hard coat surface layer. In some embodiments, themultilayer panels or laminates include a pair of rigid substrates withthe resin interlayer disposed therebetween. In other embodiments, themultiple layer panels include a rigid substrate and a cellulose esterinterlayer with a non-cellulose ester layer between them, optionallyincluding a tie layer, adhesive coating and/or adhesion promoter asneeded.

In various embodiments, the interlayers of the present invention willmost commonly be utilized in multiple layer panels comprising twosubstrates, typically a pair of glass substrates, with the interlayersdisposed between the two substrates. An example of such a constructwould be: glass/interlayer/glass, wherein the interlayer can compriseany of the interlayers described above. These examples of multiple layerpanels are in no way meant to be limiting, as one of ordinary skill inthe art would readily recognize that numerous constructs other thanthose described above could be made with the interlayers of the presentinvention.

The interlayers described herein can be laminated between glass usingtechniques known in the art. The typical glass lamination processcomprises the following steps: (1) assembly of the two substrates (e.g.,glass) and interlayer; (2) heating the assembly via an IR radiant orconvective means for a short period; (3) passing the assembly into apressure nip roll for the first deairing; (4) heating the assembly asecond time to about 50° C. to about 120° C. to give the assembly enoughtemporary adhesion to seal the edge of the interlayer; (5) passing theassembly into a second pressure nip roll to further seal the edge of theinterlayer and allow further handling; and (6) autoclaving the assemblyat temperatures between 135 and 150° C. and pressures between 150 psigand 200 psig for about 30 to 90 minutes. Other means for use inde-airing of the interlayer-glass interfaces (steps 2 to 5) known in theart and that are commercially practiced include vacuum bag and vacuumring processes in which a vacuum is utilized to remove the air. Analternate lamination process involves the use of a vacuum laminator thatfirst de-airs the assembly and subsequently finishes the laminate at asufficiently high temperature and vacuum.

In various embodiments, the interlayers of the present invention can beused in structural applications that require maintaining good modulus athigher temperatures, such as outdoor applications that undergo regularintermittent stresses, caused by such factors as walking or running, orthat are load bearing under temperature conditions that exceed 35° C.Examples of applications include stairs, outdoor platforms, pavement orsidewalk platforms, single side balcony laminates, canopies, supportbeams, stairs, handrails, building envelopes, bullet proof glass, andbomb blast resistant glass.

The preferred forms of the invention described above are to be used asillustration only, and should not be used in a limiting sense tointerpret the scope of the present invention. Modifications to theexemplary embodiments, set forth above, could be readily made by thoseskilled in the art without departing from the spirit of the presentinvention.

The inventors hereby state their intent to rely on the Doctrine ofEquivalents to determine and assess the reasonably fair scope of thepresent invention as it pertains to any apparatus not materiallydeparting from but outside the literal scope of the invention as setforth in the following claims. This invention can be further illustratedby the following examples of embodiments thereof, although it will beunderstood that these examples are included merely for the purposes ofillustration and are not intended to limit the scope of the inventionunless otherwise specifically indicated.

EXAMPLES Example 1

Multilayer interlayers were produced with a cellulose acetate propionate(“CAP”) layer interposed between two ethylene vinyl acetate (“EVA”)layers to determine the structural capabilities of such interlayers.Sheets of photovoltaic grade formulated EVA from multiple suppliers werecut to 12 inch by 12 inch size. In addition, sheets of extrudedCAP-482-20 Tenite Propionate 380A4000015 (CAP) (from Eastman ChemicalCompany) having about 16 wt. % (19 phr) 3GEH plasticizer were also cutto 12 inch by 12 inch size. The EVA and CAP sheets were conditioned inthe cabinet at 85° F. and 24% RH for 18 to 24 hours before laying up.Glass sheets of 2.3 mm thickness were also cut to 12 inch by 12 inchsize and washed. The sheets were then used to make glass laminates witha trilayer A/B/C interlayer structure having EVA sheets in the A and Cpositions and the CAP sheet in the B position. The laminate was thenplaced in the lower chamber of a vacuum laminator and was heated at 145°C. from the bottom of the vacuum laminator (which consisted of twochambers, an upper chamber and a lower chamber separated by a flexiblerubber sheet). During the de-air cycle (5 minutes) a vacuum was pulledin both the upper and lower chambers such that the laminate was heldunder vacuum (100 to 120 Pa) without pressure. This was followed by thepress cycle (25 minutes) where the air was vented from the upper chamberallowing the atmospheric pressure to enter the upper chamber forcing therubber sheet to press onto the laminate at 1 atmosphere pressure. Table1 shows the configuration of the laminates.

TABLE 1 Samples “A” Sheet “B” Sheet “C” Sheet 1 EVA (5 mil)  CAP (30mil) EVA 2 EVA (10 mil) CAP (30 mil) EVA 3 EVA (20 mil) CAP (30 mil) EVA

The optical properties (i.e., haze, yellowness index, and lighttransmission) were measured for the produced interlayers in accordancewith the tests described herein to determine the effect that thethickness of the EVA layers had on the interlayers. In the first opticaltests, EVA/CAP/EVA interlayers were tested having a CAP core layer witha thickness of 30 mil, while the EVA layers had varying thicknesses of 5mil, 10 mil, and 20 mil each. FIGS. 10 to 12 depict the haze, yellownessindex, and light transmission measurements for the tested interlayers.As shown in FIGS. 10 to 12, the produced interlayers all exhibiteddesirable optical properties and the thickness of the EVA layers hadlittle effect on the optical properties of the interlayers.

Additionally, the optical properties (i.e., haze, yellowness index, andlight transmission) were measured for the produced interlayers inaccordance with the tests described herein to determine the effect thatthe thickness of the CAP layers had on the interlayers. Table 2 showsthe configuration of the laminates. In the second optical tests,EVA/CAP/EVA interlayers were tested having EVA skin layers with athickness of 20 mil, while the CAP core layers had varying thicknessesof 7 mil, 15 mil, and 30 mil. FIGS. 13 to 15 depict the haze, yellownessindex, and light transmission measurements for the tested interlayers.As shown in FIGS. 13 to 15, the produced interlayers all exhibiteddesirable optical properties and the thickness of the CAP layers hadlittle effect on the optical properties of the interlayers.

TABLE 2 Samples “A” Sheet “B” Sheet “C” Sheet 1 EVA (20 mil) CAP (30mil) EVA 2 EVA (20 mil) CAP (15 mil) EVA 3 EVA (20 mil) CAP (7 mil)  EVA

Furthermore, the compressive shear adhesion was measured between the EVAand CAP layers. FIG. 16 depicts the results of these measurements andthe thicknesses of the tested EVA and CAP layers. As shown in FIG. 16,the interlayers exhibited excellent adhesion between the EVA and CAPlayers.

In addition, the EVA/CAP/EVA interlayers were tested using the meanbreak height test according to ANSI/SAE Z26.1-1996, which is describedabove. The results of this test are depicted in FIG. 17, which alsoprovides the thickness of the tested EVA and CAP layers. As shown inFIG. 17, the tested interlayers exhibited excellent impact performance,especially with CAP layers having a thickness of 30 mil.

Moreover, the impact performance of unformulated EVA was compared to theabove described commercial formulated EVA in the interlayers. As shownin FIG. 18, interlayers produced with unformulated EVA did not performas well as interlayers produced with formulated EVA when subjected tothe mean break height test according ANSI/SAE Z26.1-1996.

Accordingly, the EVA/CAP/EVA films produced herein demonstrated veryhigh stiffness and, thus, can serve as an advanced structuralinterlayer. Furthermore, it is expected that other cellulose esters willdemonstrate similar visual and mechanical properties and would also beexcellent candidates for structural interlayers.

Example 2

It was additionally demonstrated that EVA can be used as a tie layer toincrease the adhesion between a polyvinyl butyral (“PVB”) layer and acellulose acetate propionate (“CAP”) layer while retaining the impactperformance and rigidity of the composite interlayer. Generally, thereis limited adhesion between PVB and CAP and one way to solve the problemis to use a tie layer. A formulated EVA (VISTASOLAR®) layer was used toincrease adhesion between a PVB layer and CAP layer.

Interlayer films having a PVB/EVA/CAP/EVA/PVB configuration wereproduced by laying separate films of each material via the hand lay-upmethod, which is well known in the art. This EVA used in the interlayerswas produced in a pilot plant by Solutia Inc., a subsidiary of EastmanChemical Company (Springfield, Mass.) and contained an EVA with a VAcontent of 28%, a silane additive, a peroxide additive, a co-activator,a UV blocker, and an antioxidant. The CAP was CAP-482-20 TenitePropionate 380A4000015 used in the previous example (with 19 phr (16 wt.%) 3GEH plasticizer). The PVB was Saflex® RB11, a commercially availablePVB interlayer that contains a plasticizer, a UV blocker, an antioxidantand adhesion control agents from Solutia Inc., a subsidiary of EastmanChemical Company. The CAP layer had a thickness of 30 mil, the EVAlayers each had a thickness of 5 mil, and the PVB layers each had athickness of about 15 mil. The resulting interlayers were cut to 12inches by 12 inches. The interlayers were laminated between two glasssheets of annealed glass each having thicknesses of 2.3 mm. Thelamination process utilized a vacuum laminator, as described above, tolaminate all samples, which involved: (1) placing the samples on thevacuum laminator lower chamber; (2) applying a vacuum for 5 minutesfollowed by 25 minutes in at 1 atmospheric pressure and 145° C.; and (3)cooling the laminates to room temperature. Ten samples were producedusing this lamination technique. In addition, ten separate samples wereproduced using the above lamination process, except they were pressed ata temperature of 155° C.

The above samples were tested using the mean break height test accordingto ANSI/SAE Z26.1-1996, which is described above. The results of thistest are depicted in FIG. 19. According to the tests, no delamination atany of the interlayer interfaces as a result of the impacts wereobserved, thereby indicating excellent interfacial adhesion. Inaddition, the average impact performance of the interlayers was verygood.

It was also observed that EVA layers bind very well to both PVB and CAPlayers, thus helping to increase the adhesion between these layers. Inaddition, the presence of the EVA layers did not negatively affect theoptical and structural properties of the interlayers.

Example 3

Multilayer interlayers laminated between glass were produced with acellulose acetate propionate layer (CAP) interposed between twothermoplastic polyurethane (“TPU”) layers to determine the structuralcapabilities of such interlayers.

Interlayers having a TPU/CAP/TPU configuration were assembled. The TPUused in this study was A4700NAT (from Deerfield Urethane). The CAP wasCAP-482-20 Tenite Propionate 380A4000015 used in the previous examples(with 19 phr (16 wt. %) 3GEH plasticizer). The CAP layer had a thicknessof 30 mil, while the TPU layers each had a thickness of 15 mil. Theresulting interlayers were cut to 12 inches by 12 inches. A total of teninterlayer samples were produced.

The ten interlayer samples were laminated between two annealed glasssheets having thicknesses of 2.3 mm and a dimension of 12 inches by 12inches. The lamination process utilized a vacuum laminator, as describedabove, to laminate all samples, which involved: (1) placing the sampleson the vacuum laminator lower chamber; (2) applying a vacuum for 5minutes followed by 25 minutes in at 1 atmospheric pressure and 145° C.;and (3) cooling the laminates to room temperature. Ten samples wereproduced using this lamination technique.

The above samples were tested using the mean break height test accordingto ANSI/SAE Z26.1-1996. The average Mean Break Height was about 25 feet,which indicated good impact performance. In addition, the compressiveshear adhesion was measured between the TPU and CAP layers to determineadhesion strength. Measurements were taken on five samples at the edgeof the laminates and three samples at the center of the laminates bycutting 3 cm discs from these locations. These results of themeasurements are depicted in Table 3, below.

TABLE 3 Position MPa on 3 cm Disc Sample 1 2 3 4 5 Average MPa Edge12.90 9.20 9.12 6.54 12.19 10.4 Center 11.88 10.19 11.18 N/A N/A

As shown above, the adhesion testing showed that the interlayers had anaverage compressive shear adhesion strength of 10.4 MPa. Thus, thisdemonstrated that there was desirable adhesion between the TPU and CAPlayers.

Furthermore, the haze and optical properties of three different sampleswere tested according to the test procedures described herein.Measurements were taken on the three samples at the edge of thelaminates and the center of the laminates by cutting 3 cm discs fromthese locations. The optical measurements were conducted using anUltraScan Pro 1024 from Hunter Lab.

TABLE 4 Sample YI D1925 % Haze Edge 1 −0.43 1.0 Edge 2 −0.45 1.1 Edge 3−0.49 0.9 Average −0.457 1.0 Center 1 −0.45 1.0 Center 2 −0.46 1.1Center 3 −0.48 1.1 Average −0.463 1.1

Based on the haze tests, the interlayers exhibited a low haze percentageof 1.1% or less. Accordingly, these interlayers exhibited good rigidity,good impact performance, and allowed desirable clarity when laminatedinto a glass panel.

Example 4

This study was undertaken to demonstrate that a thermoplasticpolyurethane (“TPU”) tie layer can be used to increase the adhesionbetween a polyvinyl butyral (“PVB”) layer and a cellulose acetatepropionate (“CAP”) layer while retaining the impact performance andrigidity of the composite interlayer.

For this study, interlayer films having a PVB/TPU/CAP/TPU/PVBconfiguration were produced by laying separate films of each materialvia the hand lay-up method using the same TPU (15 mil), CAP (30 mil) andPVB (15 mil) as in the above Examples (using the same materialspreviously described). The resulting interlayers were cut to 12 inchesby 12 inches. The interlayers were laminated between two annealed glasssheets each having thicknesses of 2.3 mm. The lamination processutilized a vacuum laminator to laminate all samples, which involved: (1)placing the samples on a conveyer and covering them with Teflon byDuPont; (2) applying a vacuum for 5 minutes followed by 25 minutes in apress at 145° C.; and (3) cooling the laminates to room temperature. Tensamples were produced using this lamination technique. In addition, tenseparate samples were produced using the above lamination process,except they were pressed at a temperature of 155° C. Five samples thatwere laminated at 145° C. and ten samples that were laminated at 155° C.were tested using the mean break height test according to ANSI/SAEZ26.1-1996.

Limited delamination in only some of the tested interlayer interfaces asa result of the impacts was observed, thereby indicating goodinterfacial adhesion. In addition, the average impact performance wasover 36 feet for samples produced at both temperatures and wasconsidered desirable. The TPU layers bind very well to both PVB and CAPlayers, thus helping to increase the adhesion between these layers.

Example 5

A study was conducted to determine if a silane compound applied on thesurface of the CAP layer (produced using the same CAP and plasticizer asin the above examples) could increase adhesion to PVB. A solution wasprepared by adding 25 wt. % of silane (Xiameter OFS-6020(N-(3-(trimethoxysilyl)propyl) ethylenediamine)) into methanol. Thesurfaces of the CAP sheets were then spray coated using the silanesolution by adding the solution into the cup of an airbrush in thedesired amount (1 ml in this Example) and applying it to the surface ofthe CAP sheets, and the spray coated sheets were hung to air dry.Interlayer films having a PVB/CAP/PVB configuration were then producedby laying separate films of each material together via the hand lay-upmethod, which is well known in the art. The PVB was Saflex® DG41, acommercially available PVB interlayer that contains a plasticizer, a UVblocker, an antioxidant and adhesion control agents from Solutia Inc., asubsidiary of Eastman Chemical Company. The CAP layer had a thickness ofabout 30 mil and the PVB layers each had a thickness of about 30 mil.The resulting interlayers were cut to 6 inches by 9 inches. Theinterlayers were laminated between two glass sheets of annealed glasseach having thicknesses of 2.3 mm. The lamination process utilized avacuum laminator, as described above, to laminate all samples, whichinvolved: (1) placing the samples on the vacuum laminator lower chamber;(2) applying a vacuum for 5 minutes followed by 25 minutes in at 1atmospheric pressure and 145° C.; and (3) cooling the laminates to roomtemperature. The compressive shear adhesion was measured between the PVBand CAP layers to determine adhesion strength. It was found that thecompressive shear adhesion of the interlayers comprising the silanesolution was 26.5 MPa. Thus, this demonstrates that the use of thesilane compound as an adhesion promoter helped to provide desirableadhesion between the PVB and CAP layers.

Example 6

Blends of CAP-504-0.2 Tenite Propionate (CAP) (from Eastman ChemicalCompany) and PVB resin (from Solutia Inc., a subsidiary of EastmanChemical Company) were extruded into sheets after a plasticizer (35 phr3GEH plasticizer was added to the blend of resins), adhesion controlsalts and an antioxidant were added. The blends were made at two blendlevels: 80% PVB:20% CAP and 70% PVB:30% CAP. The films were then cut to6 inch by 6 inch size sheets. Glass sheets of 2.3 mm thickness were alsocut to 6 inch by 6 inch size and washed. The sheets were then used tomake glass laminates with a trilayer A/B/C interlayer structure havingPVB (Saflex® RB41) sheets in the A and C positions and the CAP/PVB blendsheet in the B position. The laminate was then placed in the lowerchamber of a vacuum laminator and was heated at 145° C. from the bottomof the vacuum laminator (which consisted of two chambers, an upperchamber and a lower chamber separated by a flexible rubber sheet).During the de-air cycle (5 minutes) a vacuum was pulled in both theupper and lower chambers such that the laminate was held under vacuum(100 to 120 Pa) without pressure. This was followed by the press cycle(25 minutes) where the air was vented from the upper chamber allowingthe atmospheric pressure to enter the upper chamber forcing the rubbersheet to press onto the laminate at 1 atmosphere pressure. The haze ofthe laminates was then measured, and the blend having 30% CAP and 70%PVB exhibited a haze value of about 0.4% while the blend having 20% CAPand 80% PVB exhibited a haze value of about 0.2%, showing that blends ofCAP and PVB can be made that exhibit desirable very low haze.

Definitions

It should be understood that the following is not intended to be anexclusive list of defined terms. Other definitions may be provided inthe foregoing description, such as, for example, when accompanying theuse of a defined term in context.

As used herein, the terms “a,” “an,” and “the” mean one or more.

As used herein, the term “and/or,” when used in a list of two or moreitems, means that any one of the listed items can be employed by itselfor any combination of two or more of the listed items can be employed.For example, if a composition is described as containing components A,B, and/or C, the composition can contain A alone; B alone; C alone; Aand B in combination; A and C in combination, B and C in combination; orA, B, and C in combination.

As used herein, the terms “comprising,” “comprises,” and “comprise” areopen-ended transition terms used to transition from a subject recitedbefore the term to one or more elements recited after the term, wherethe element or elements listed after the transition term are notnecessarily the only elements that make up the subject. As used herein,the terms “having,” “has,” and “have” have the same open-ended meaningas “comprising,” “comprises,” and “comprise” provided above. As usedherein, the terms “including,” “include,” and “included” have the sameopen-ended meaning as “comprising,” “comprises,” and “comprise” providedabove.

As used herein, the term “about” refers to values within ten percent ofthe recited value. The present description uses numerical ranges toquantify certain parameters relating to the invention. It should beunderstood that when numerical ranges are provided, such ranges are tobe construed as providing literal support for claim limitations thatonly recite the lower value of the range as well as claim limitationsthat only recite the upper value of the range. For example, a disclosednumerical range of 10 to 100 provides literal support for a claimreciting “greater than 10” (with no upper bounds) and a claim reciting“less than 100” (with no lower bounds).

What is claimed is:
 1. A multilayer interlayer comprising: (a) anon-cellulose ester layer comprising a poly(vinyl acetal) resin; (b) acellulose ester layer comprising at least one cellulose ester having ahydroxyl content of at least 0.5 weight percent based on the entireweight of the cellulose ester, wherein said cellulose ester layer has aglass transition (“Tg”) temperature of at least 50° C.; and (c) anadhesive coating comprising at least one silicone-containing compound,wherein said adhesive coating is at least partially interposed betweensaid non-cellulose ester layer and said cellulose ester layer.
 2. Themultilayer interlayer of claim 1, wherein said adhesive coatingcomprises at least 1 weight percent of said silicone-containingcompound.
 3. The multilayer interlayer of claim 1, wherein said adhesivecoating comprises at least 50 weight percent of said silicone-containingcompound.
 4. The multilayer interlayer of claim 1, wherein saidsilicone-containing compound comprises at least one alkoxysilane.
 5. Themultilayer interlayer of claim 4, wherein said alkoxysilane comprisesγ-glycidoxypropyltrimethoxysilane,aminoethylaminopropyltrimethoxysilane, or a combination thereof.
 6. Themultilayer interlayer of claim 1, wherein said multilayer interlayerexhibits a compressive shear adhesion between said cellulose ester layerand said adhesion coating of at least 5 MPa.
 7. The multilayerinterlayer of claim 1, wherein the cellulose ester comprises at leasttwo different acyl groups selected from acetate, propionate, butyrate,other acyl groups and combinations thereof.
 8. The multilayer interlayerof claim 7, wherein the cellulose ester comprises at least two ofacetate, propionate and butyrate groups and combinations thereof.
 9. Themultilayer interlayer of claim 1, wherein said poly(vinyl acetal) resincomprises polyvinyl butyral.
 10. The multilayer interlayer of claim 1,wherein said cellulose ester layer exhibits a shear storage modulus thatis greater than the shear storage modulus of said non-cellulose esterlayer.
 11. A multilayer interlayer comprising: (a) a first non-celluloseester layer comprising a poly(vinyl acetal) resin; (b) a cellulose esterlayer comprising at least one cellulose ester having a hydroxyl contentof at least 0.5 weight percent based on the entire weight of thecellulose ester, wherein said cellulose ester layer has a glasstransition (“Tg”) temperature of at least 50° C.; (c) a first adhesivecoating comprising at least one silicone-containing compound, whereinsaid first adhesive coating is at least partially interposed betweensaid first non-cellulose ester layer and said cellulose ester layer; (d)a second non-cellulose ester layer comprising a poly(vinyl acetal)resin; and (e) a second adhesive coating comprising at least onesilicone-containing compound, wherein said second adhesive coating is atleast partially interposed between said second non-cellulose ester layerand said cellulose ester layer.
 12. The multilayer interlayer of claim11, wherein said silicone-containing compound comprises at least onealkoxysilane.
 13. The multilayer interlayer of claim 11, wherein thecellulose ester comprises at least two different acyl groups selectedfrom acetate, propionate, butyrate, other acyl groups and combinationsthereof.
 14. The multilayer interlayer of claim 13, wherein thecellulose ester comprises at least two of acetate, propionate andbutyrate groups and combinations thereof.
 15. A laminate comprising themultilayer interlayer of claim
 14. 16. The multilayer interlayer ofclaim 11, wherein the first non-cellulose ester layer and the secondnon-cellulose ester layer comprise a plasticizer.
 17. The multilayerinterlayer of claim 11, wherein the cellulose ester layer comprises aplasticizer.
 18. A multilayer interlayer comprising: (a) a non-celluloseester layer comprising a poly(vinyl acetal) resin and a plasticizer; (b)a cellulose ester layer comprising at least one cellulose ester having ahydroxyl content of at least 0.5 weight percent based on the entireweight of the cellulose ester and a plasticizer, wherein said celluloseester layer has a glass transition (“Tg”) temperature of at least 70°C.; and (c) an adhesive coating comprising at least onesilicone-containing compound, wherein said adhesive coating is at leastpartially interposed between said non-cellulose ester layer and saidcellulose ester layer.
 19. The multilayer interlayer of claim 18,wherein said silicone-containing compound comprises at least onealkoxysilane.
 20. A laminate comprising the multilayer interlayer ofclaim 18.